TW202327979A - Stack pusher - Google Patents

Abstract

The present application discloses a robotic stack pusher system, and a method and a computer system for controlling the robotic stack pusher system. The robotic stack pusher system includes an actuation device and a plurality of pusher structures that are substantially planar. At least one of the plurality of pusher structures is nested within one or more other pusher structures of the plurality of pusher structures. The actuation device is the actuation device is operatively coupled to at least one of the plurality of pusher structures. The actuation device is configured to actuate a position of the plurality of pusher structures between a retracted state and an extended state in response to a control signal. Actuation of the actuation device causes the one of the plurality of structures that is nested to extend telescopically with sufficient force and to controllably push a payload

Description

stack pusher

In certain warehouses and similar operations, a set of tasks sometimes referred to as "kitting" may be performed to assemble pallets of stacked items for further distribution, such as delivery to a retail point of sale. Stacks of pallets containing items of the same type can be received, and pallets can be drawn from different homogeneous stacks of pallets each having a corresponding type of item to assemble a mixed stack of pallets, eg, to send to a given destination.

For example, a bakery may bake different types of products and may fill stackable trays each with a corresponding homogenous type of product, such as a particular type of bread or other baked goods. Stacks of trays may be provided by a bakery, for example, to a distribution center. One stack may contain trays for loaves of sliced white bread, another stack may have trays for loaves of whole wheat bread, another tray for blueberry cupcake wrappers, etc. Trays can be drawn from various stacks to assemble a (possibly) mixed pallet stack. For example, a stack of six trays of white bread, three trays of whole wheat bread, and one tray of blueberry cupcakes may be assembled, for example, for delivery to a retail store.

Although the above examples refer to trays of different types of baked goods, in other line preparation operations, stackable trays can hold other products.

In a typical approach, pallets are handled by human workers. The tray may include handles to enable a human worker to grab and move the tray, for example, by placing the worker's hand on or in the handle. Such work performed by human workers can result in fatigue or injury, can take a significant amount of time to complete, and can be prone to error.

Cross References to Other Applications

This application claims priority to U.S. Provisional Patent Application No. 63/254,914, filed October 12, 2021, and entitled "STACK PUSHER," which is incorporated by reference for all purposes In this article.

The invention can be implemented in numerous ways, including as a program; an apparatus; a system; a composition of matter; a computer program product embodied on a computer readable storage medium; and/or a processor, such as configured to execute A processor of instructions stored on or provided by a memory coupled to the processor. In this specification, these implementations, or any other form that the invention may take, may be referred to as techniques. In general, the order of steps of disclosed processes may be altered within the scope of the invention. Unless otherwise stated, a component such as a processor or a memory stated as being configured to perform a task may be implemented as a general-purpose component temporarily configured to perform the task at a given time or manufactured to perform A specific component of this task. As used herein, the term "processor" refers to one or more devices, circuits and/or processing cores configured to process data, such as computer program instructions.

A detailed description of one or more embodiments of the invention is provided below along with accompanying figures that illustrate the principles of the invention. The invention is illustrated in conjunction with these embodiments, but the invention is not limited to any embodiment. The scope of the invention is limited only by the claims and the invention encompasses numerous alternatives, modifications and equivalents. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. These details are provided for the purpose of example and the invention may be practiced in accordance with the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been set forth in detail so that the invention is not unnecessarily obscured.

As used herein, a vehicle means a truck, a cart, a cart, carrier, trailer, pallet, or one or more vehicles configured to hold or support such as pallets (e.g., a stack of pallets). Other structures of articles.

As used herein, a stock preparation system includes a robotic arm configured to move one or more objects, such as in conjunction with an assembly kit and/or a packaging kit. In various embodiments, a stock preparation machine as disclosed herein may include one or more stock rack machine modules each including a modular component.

Various embodiments include systems and methods for loading a payload into a robotic workspace or otherwise into a robotic stack mover system, which in turn moves the payload to the robotic workspace. The method includes: determining to load a payload into a robot workspace; in response to determining to load a payload into the robot workspace, controlling a robotic stack pusher system to move one or more pusher structures such that the effective advancing a load from a payload buffer zone to a final position; and controlling the robotic stack pusher system to apply a retracting force to retract one or more pusher structures to a starting position. In some embodiments, the robotic workspace includes a robotic stack mover system configured to move one or more payloads to an operable scope.

Various embodiments include a robotic stack mover system configured to load a payload into a robotic workspace or otherwise into a robotic stack mover system that The payload is then moved to the robot workspace. In some embodiments, a robotic stack pusher system includes an actuation device and one or more pusher structures. The actuation device is operatively coupled to at least one of the one or more pusher plates. The actuation device is configured to actuate a position of the one or more pusher structures between a retracted state and an expanded state. The actuation device is controlled to actuate the position of the one or more pusher structures in conjunction with loading a payload into a robotic workspace.

Various embodiments include a robotic stack mover system configured to load a payload into a robotic workspace or otherwise into a robotic stack mover system, the robotic stack mover system The payload is then moved to the robot workspace. In some embodiments, a robotic stack pusher system includes an actuation device and a plurality of pusher structures. The plurality of pusher structures are substantially planar and at least one of the plurality of pusher structures nests within one or more other of the plurality of pusher structures. The actuation device is operatively coupled to at least one of the one or more pusher structures. The actuation device is configured to actuate a position of the one or more pusher structures between a retracted state and an expanded state in response to a control signal. Actuation of the actuation means causes one of the plurality of structures to telescopically expand and controllably propel a payload with sufficient force. In some embodiments, the control signals are received from a robotic control system. The robotic control system is associated with a robotic workspace, and the robotic control system uses information obtained from one or more sensors at the robotic workspace in conjunction with generating control signals. The robotic control system uses information obtained from one or more sensors to detect a payload in a buffer zone ready to be propelled. Such as in conjunction with the robot control system controlling/implementing a high-level plan to perform stocking operations using a robotic arm relative to items to be picked from/to be placed into the payload, the robot control system responding to detecting that the payload is in the buffer In the zone and ready to be advanced into the workspace (eg, inserted into the workspace) it is determined to control the robotic stack pusher via the control signal.

According to various embodiments, a robotic stack pusher system includes an actuation device and a plurality of pusher structures. The pusher structures of the plurality of pusher structures are nested when the system is in a retracted state. For example, any one pusher structure is at least partially enveloped by a previous pusher structure (if any) in the system. The system controls actuators that cause the plurality of pusher structures to telescopically expand from a retracted state to an expanded state. When the plurality of pusher structures are expanded to the expanded state, at least one of the pusher structures engages a payload (e.g., such as a stack of receptacles on a cart) to load the payload into the robot workspace (e.g., Loaded into a robotic stack mover system configured to move the payload through the robot workspace (e.g., move the payload into the operational range of one or more robots such that the ( etc.) the robot performs a stocking operation relative to the payload). The stocking operation includes unloading a set of receptacles (e.g., trays) in the payload. For example, the robot picks up an item from a receptacle in the payload and places the item On a transport structure or other destination location. Staging operations include loading a set of receptacles into a payload. For example, the payload is a stack of empty pallets. A robot carries items from a source location (e.g., to One of the robot workspaces is the transport structure) to pick up items, and the robot places the items in the tray in sequence.

According to various embodiments, a robotic stack mover system is configured to load a payload (eg, a stack of pallets, such as a stack on a cart) to a payload introduction location of a robotic stack mover system. The robotic stack mover system is configured to receive a plurality of vehicles (e.g., trolleys) including payloads (e.g., stacks of pallets on the vehicles) and autonomously move at least one of the vehicles to one within reach of a robotic arm destination location. The robotic arm is controlled to move (eg, pick and place) items (eg, a pallet comprising a plurality of items) to/from a carrier (eg, to/from a pallet stack). In various embodiments, the system determines to move the vehicle to/from the vehicle in conjunction with determining that an item is to be moved to/from the vehicle (e.g., in response to determining that a stack of items included in the vehicle is to be unstacked). destination location. The system determines a plan for moving the item to a destination location, such as within a range/workspace of a robotic arm, such as a specific robotic arm among a plurality of robotic arms included in a stock preparation system. In response to a determination that the vehicle is to be moved, the system controls to move the vehicle to the destination location (eg, according to a determined plan). For example, the system actuates a drive unit (eg, the system drives a motor) to cause the vehicle to move to a destination location. In response to determining that a stocking operation performed with respect to the vehicle is complete (e.g., all items are unstacked from the vehicle, a stack of a group of items is complete, etc.), the system controls to move the vehicle to a vehicle return position and/or move another vehicle to a destination location. Additionally, in response to determining that a stocking operation performed relative to the vehicle is complete, the system controls the robotic stack pusher system to move another payload (e.g., a payload on a vehicle such as a cart) to the payload introduction position, And the robotic stack mover system is controlled to move the next payload to the destination location.

According to various embodiments, a system (eg, a robotic stack pusher system) includes a set of one or more pusher structures. For example, the system includes at least one payload engaging pusher structure (eg, a pusher structure that engages a pallet stack to move the pallet stack to a destination location). The system controls to move (eg, linearly expand) the payload engaging pusher structure from a retracted position to an extended position to engage the payload. In some embodiments, the system includes a plurality of pusher structures including at least a payload engaging pusher structure and a first pusher structure. The plurality of pusher structures further includes one or more intermediate pusher structures. Where the system includes a plurality of pusher structures, the system controls to move the pusher structures to telescopically expand to the expanded position. The pusher structures expand sequentially from their respective respective retracted positions. For example, when the system controls movement of a thruster structure, the system controls to move the payload engaging the thruster structure to move to be expanded relative to other thruster structures. In response to the payload engaging the thruster structure being expanded to a threshold point (eg, the payload engaging the thruster structure is fully expanded relative to the other thruster structures), the system controls to expand the other thruster structures in sequence. The pusher structure corresponds to a plate or other planar structure (eg, substantially planar structure) or assembly stacked on top of each other in a nested configuration. When the system is in a retracted state, the thruster structures are in a nested configuration, and when the system controls to move the payload, the system controls an actuation device that causes the thrusters Structures are sequentially expanded relative to their respective subsequent thruster structures (e.g., the subsequent thruster structure is the next thruster to be moved/expanded after the current thruster structure is moved to expand relative to the subsequent thruster structure device structure). If the system includes a payload engaging thruster structure, a first thruster structure, and one or more intermediate thruster structures, the thruster structures are configured/configured such that when the operating system is to be transitioned into a configuration in an extended state (e.g. , to propel the payload), the payload engaging propeller structure is first expanded relative to the other propeller structures, then one or more intermediate propeller structures are expanded relative to each other, and then the first propeller structure is expanded relative to A base plate is extended to which a plurality of pusher structures are operatively connected.

In some embodiments, movement of the control system from an expanded state to a retracted state causes the plurality of pusher structures to be closer to the proximal end or base of the system than the current pusher structure relative to a previous pusher structure (e.g., closer to the proximal end or base of the system than the current pusher structure One of the propeller structures of the plates) is retracted sequentially. As an example, the order in which the pusher plates are moved to a retracted position/state is the same as the order in which the plurality of pusher plates are expanded. For example, if the system includes a payload engaging thruster structure, a first thruster structure, and one or more intermediate thruster structures, the thruster structures are configured/configured such that when operation will be configured to transition to a When the system is in the retracted state (e.g., with the pusher structure retracted to allow another payload to be loaded in a buffer zone for introduction into a robotic stack mover system), the payload engages the pusher structure first relative to the The other pusher structures are retracted, then one or more intermediate pusher structures are retracted sequentially relative to each other, and then the first pusher structure is retracted relative to a base plate, the plurality of pusher structures A structure is operatively connected to the base plate.

In certain embodiments, the system includes a plurality of thruster structures that, when the system transitions to an extended state (e.g., to propel a payload to a destination location) or a retracted state (e.g., to allow a subsequent effective The plurality of propeller structures telescopically expands/retracts when a load is loaded into the buffer zone). The use of multiple pusher structures that telescopically expand/retract sequentially improves the efficiency of the system for propelling payloads (eg, stacks of pallets). For example, a system that includes telescopically expanding/retracting nested pusher structures is more space efficient than a system that includes a single pusher structure that expands linearly from a starting location (e.g., a base plate), thus It is because a plurality of thruster structures are nested. Cascading and offset stages (eg, offset of the plurality of pusher structures) allow the system to be compact (eg, when in the retracted state). As another example, the system is more cost effective than one that includes a single pusher configuration that expands linearly from the starting position. The system size, compactness and functionality meet regulatory or other requirements for mobile payloads and allow deployment within an available/specified installation space. The propeller structure is optionally sized based on the size of the space in which the system will be deployed (eg, in a warehouse). In certain embodiments, a pusher structure (e.g., a payload engaging pusher structure) advances one of the payloads corresponding to delivery vehicle. For example, a pusher structure engages and propels a frame of the vehicle to cause the vehicle to move within the workspace. The pusher structure is nested and has a low profile to ensure that the stack pusher system does not engage items stacked on a vehicle (eg, wheeled dolly). In certain embodiments, the payload engages the propeller structure to engage the payload (eg, a wheeled dolly) within 12 inches of the ground. In certain embodiments, the payload engages the propeller structure to engage the payload (eg, a wheeled dolly) within 6 inches of the ground. In certain embodiments, the payload engages the propeller structure to engage the payload (eg, a wheeled dolly) within between 4 inches and 8 inches of the ground.

The system is configured to move the pusher structure between the expanded state and the retracted state based on control of an actuation device that actuates a linear force applied to the pusher structure. As the thruster structure moves from a retracted state to an expanded state, the direction of the linear force is from one of the base plates of the system to the final position where the system loads the payload to the destination position. Conversely, when the pusher structure is moved from an expanded state to a retracted state, the direction of the linear force is from the final position towards the base plate. Various pusher mechanisms can be implemented to control/apply linear force to the pusher structure. In some embodiments, the linear force is applied by a linear axis, the position of which is controlled by the consistent force of the propulsion mechanism. Examples of propulsion mechanisms include: (i) air or hydraulic pistons, (ii) linear actuators, and (iii) rack/pinion or other linear gear mechanisms driven by electric motors, etc. In some embodiments, a linear force is applied to the payload engaging pusher structure causing the payload engaging pusher structure to move between a retracted position and an expanded position. The payload engaging pusher structure is operatively connected to other pusher structures in the set of pusher structures such that the payload engages the pusher structure and then applies a linear force causing the other pusher structures in their respective retracted positions and through. Move between extended locations. As an example, the payload engaging propeller structure is operatively connected to other propeller structures via a series of pulley struts and wire rope cables or chains.

In some embodiments, the system includes a gating structure controlled to actuate a gate to move to a closed position or an open position. When the gate is configured to be in the closed position, the gate prevents/impedes movement of the payload from the buffer zone/zone to the destination location (eg, where the payload will be introduced to the robotic stack mover system). When the gate is configured to be in the open position, the robotic payload pusher system (eg, the robotic stack pusher system) loads a payload into the robotic workspace. For example, a robotic payload pusher system advances the payload to a destination location, such as a location where the payload is introduced into a robotic stack mover system.

In some embodiments, the system includes a controlling computer. The system uses a control computer to control the actuation device (e.g., to actuate a force such as a linear force to move the robotic stack pusher system between an expanded state and a retracted state) and control insertion into one of the systems or a movement/position of multiple vehicles (eg, payloads such as stacks of pallets on a cart). The system may further include or be connected to a robotic arm, and the system controls the robot, such as using a control computer in conjunction with performing a stocking operation (e.g., stacking/unstacking items such as pallets, etc.) relative to one or more vehicles/payloads arm. The system may include a data structure by which the system maintains/stores: (i) a vehicle to a manifest (e.g., a packing list or information indicating a group of items included in a vehicle or items within an item). other information), (ii) a mapping of vehicle to position or relative position within the system, (iii) vehicle to robotic arm (e.g., assigned to stack/unstack items to/from the vehicle) A mapping of the robot arm, etc.), (iv) a mapping of the robot arm to a workspace or zone corresponding to a range of the robot arm, etc. The system can monitor/track a location of a vehicle/payload and update data structures such as maps etc. accordingly. The system uses data structures to track specific items (or items included in a specific item/vehicle) within the system, such as tracking a specific vehicle to which an item will be stacked, or one from which an item will be unstacked/obtained A specific vehicle (or associated manifest).

The control computer controls the robotic stack thruster system. The control computer further controls the robotic stack mover system to move stacks within a robotic workspace and/or controls a gating structure to control a gate that blocks/permits the introduction of a payload into the robotic stack mover system. In certain embodiments, the control computer coordinates control of the robotic stack pusher system and the robotic stack mover system to introduce payloads into a robotic workspace, move payloads through the robotic workspace for processing (e.g., for the robot to perform material preparation operations), and move to a return position of a carrier (for example, a trolley). In some embodiments, the system includes a buffer transport structure that moves payloads from a source location (e.g., a location where the payload is introduced into the system) to a buffer zone where At the buffer zone, the robotic stack pusher system is used to move the payload through/over the gate (eg, in conjunction with loading the payload to the robotic stack mover system). The buffer transport structure includes a transport plane or other transport mechanism. The system performs coordinated control of two or more of a robotic stack pusher system, a robotic stack mover system, gate control structures, and buffer transport devices.

The system includes one or more sensors that capture information about a workspace (including one or more of the workspace of the robotic stack mover system), a robotic stack mover system, a Information on one or more of a buffer transport device, a gate control structure, etc. The one or more sensors include a vision system and/or various other types of sensors, including a weight sensor, a light sensor (eg, a light array), a force sensor, and the like. As an example, the system includes a light sensor(s) that detects whether the robotic stack pusher system is in an extended state or a retracted state, or detects whether the robotic stack pusher system is in an The position/location of one or more of the included propeller structures. As another example, the system includes a force sensor that detects whether a payload is engaged by a robotic stack pusher system. As another example, the system includes gate sensor(s) that detect a state of a gating structure, such as whether a gate is in an open position, a closed position, or in between open states in a position between the closed state. As another example, the system includes one or more light sensors or vision systems to detect when a payload (e.g., pallet stack) is moved through the robotic workspace by a robotic stack mover system or by a buffered transporter. Determine the position of the payloads as they move through the buffer. all or some of the one or more sensors may be included in a vision system of the system, such as a vision system that operates to obtain information about items or components in the workspace of the robotic arm, and The system uses the vision system to control a robotic arm to move items (eg, stack/unstack items relative to a vehicle).

Although the embodiments described herein are provided in the context of a stock preparation system or picking and placing items from a pallet, various embodiments can be in various other contexts (such as palletizing systems, singulation systems, etc.) implement. For example, while a robotic stack pusher system is described herein in the context of a stocking system in which a robotic arm is controlled to perform stocking operations relative to items in a payload (e.g., a stack of receptacles, etc.) , but the robotic stack pusher system is deployed in (or in conjunction with) various other systems such as a palletizing system, a singulation system, and the like. For example, robotic stack pusher systems are used in a palletizing system, such as in connection with introducing (eg, pushing) a pallet into a robotic workspace for depalletizing. As another example, a robotic stack pusher system is used in a singulation system, such as in conjunction with moving a stack of pallets including items that have been singulated.

In some embodiments, the system includes a robotic stack mover system that loads the payload into (e.g., pushes the stack of pallets into) a robotic stack mover system configured to push the payload into Move through the robot workspace. An example of a robotic stack mover system is further set forth in US patent application Ser. No. 17/713,077, filed April 4, 2022, the entire contents of which are hereby incorporated herein for all purposes.

As used herein, depalletizing includes picking an item from a pallet, such as from a stack of items on a pallet, moving the item, and placing the item at a destination location, such as a transport structure. One example of a palletizing/depalletizing system and/or process for palletizing/depalletizing a set of items is further described in U.S. Patent Application No. 17/343,609, The entire contents are hereby incorporated herein for all purposes.

As used herein, singulation of an item includes picking an item from a source stack/stream and placing the item on a transport structure (eg, a staging conveyor or similar transport device). Optionally, singulation may include sorting the various items on the transport structure, such as by individually placing the items from a source stack/flow into a slot or tray on the transport. An example of a singulation system and/or process for singulating a group of items is further set forth in U.S. Patent Application Serial No. 17/246,356, which is hereby incorporated in its entirety for all purposes In this article.

As used herein, staging includes picking one or more items/items from a corresponding location and placing one or more items in a predetermined location in such a way that a set of one or more items corresponds to a kit middle. One example of a stocking system and/or procedure for stocking a group of items is further set forth in US Patent Application Serial No. 17/219,503, which is hereby incorporated herein in its entirety for all purposes. Further described in U.S. Patent Application Serial No. 16/224,513, filed December 18, 2018, and entitled "Robotic Kitting System" (published March 26, 2020 as U.S. Patent Application Publication No. 2020/0095001) Another example of a stocking system and/or process for stocking a group of items, the contents of this US patent application are incorporated herein for all purposes.

FIG. 1A is a block diagram illustrating a robot production line material preparation system according to the related art. In the example shown, the system 100 includes source pallet stacks 102 and 104 moving along an input stack transporter 106 fed in this example from an input 108 (staging and loading area). In this example, each of source pallet stacks 102 and 104 are shown stacked on a wheeled truck or chassis. In various embodiments, the source pallet stacks 102 and 104 may be manually advanced onto the transport device 106, which may be a conveyor belt or configured to advance the source pallet stacks 102 and 104 through the transport device 106 Other structures of the workspace. In some embodiments, the chassis or other base structure upon which the active trays are stacked may be self-propelled. In some embodiments, source pallet stacks 102 and 104 may be advanced through/by transport device 106 under robotic control. For example, the speed and timing at which source pallet stacks 102 and 104 are advanced on/through transport device 106 may be controlled to facilitate efficient grabbing of pallets from source pallet stacks 102 and 104 .

In the example shown, a single track (eg, track 110 ) is disposed along one long side of transport device 106 . In this example, two robots, one robot including robot arm 112 and the other robot including robot arm 114 , are movably mounted on track 110 independently of each other. For example, each robotic arm 112 , 114 may be mounted on a self-propelled chassis that slides along track 110 . In this example, each robotic arm 112 , 114 terminates with a tray handling end effector 116 , 118 .

The pallet handling end effectors 116, 118 are operated under robotic control to grab one or more pallets from a source pallet stack 102, 104. As shown in FIG. 1A , each end effector 116 , 118 includes a transverse member attached to the end of the robotic arm 112 , 114 . A side member is mounted on each end of the cross member. As shown, in various embodiments, at least one of the side members is opened or closed under robotic control to enable grasping (by closing the side members) or release (by opening the side members) of a tray.

Each end effector 116, 118 includes a non-moving ("passive") side member and a movable ("active") side member. In this example, the movable or "active" side member swings open (where the position of the end effector 116 is shown), for example to enable the end effector to be placed in position to grasp one or more trays, and The swing is closed (where the position of the end effector 118 is shown), for example to accomplish a grab of one or more trays. A robotic control system (eg, a computer controlling the robotic arms 112, 114, such as the control computer 128) controls the end effectors to actuate the opening/closing of the end effectors, such as in conjunction with grasping or releasing a tray. The robotic control system controls the end effectors based at least in part on image data of the workspace and/or one or more sensors included in (or coupled to) the corresponding end effectors. In certain embodiments, one or more sensors included in (or coupled to) a corresponding end effector are configured to: (i) obtain an indication of a gripping mechanism of the end effector ( For example, an active component) is in an open position or a closed position, (ii) obtain information indicative of the degree of opening of the gripping mechanism, (iii) obtain information indicative of the tray (or end effector relative to the tray) Information about when to be in a position where the end effector is controlled to align at least one side of the end effector (e.g., a passive component or a structure included on the passive component) with a tray (e.g., , being engaged by a hole in one side of a pallet), a recess, or a handle, (iv) obtaining information indicating when the pallet (or an end effector relative to the pallet) is in a position where , an end effector (e.g., a passive component or a structure included on a passive component) engages with a hole, recess, or handle included in a side of a tray, and/or (v) obtains an indication of whether the gripping mechanism is closed or Information that otherwise engages with the pallet.

Each end effector 116, 118 includes one or more protrusions or similar structures on each side member having a size and shape such that the protrusions etc. fit into the side of the tray to be grasped and, in various embodiments, can slide into these holes or other openings under robotic control. For example, in some embodiments, a protrusion (sometimes referred to herein as a "thumb") on the inner face of a side member feeds into a handle (e.g., sized to fit into a hole in one's hand), as more fully described and illustrated below.

The respective robot arms 112, 114 operate fully autonomously simultaneously to pick pallets from the source pallet stacks 102, 104 and place them on the side of the track 110 opposite the transporter 106 and the source pallet stacks 102, 104 On a destination pallet stack (such as destination pallet stack 120, 122) in one of the destination pallet stack assembly areas. In various embodiments, a stack of destination pallets is assembled based on an invoice, manifest, order, or other information. For example, by selecting pallets from a respective source pallet stack 102, 104 and stacking those pallets in a corresponding destination pallet stack 120, 122 for each of a plurality of physical destinations (e.g., a retail store) to form a destination stack associated with that destination (eg, an order placed according to the destination). Completed destination pallet stacks 120, 122 (as indicated by arrow 124) are removed from the destination pallet stack assembly area, for example, to place the completed destination pallet stacks on trucks, railcars, containers, etc. Delivery to another destination, such as a retail store.

With further reference to FIG. 1A , in the example shown, the system 100 includes: a control computer 128 configured to interact with the robotic elements comprising the system 100 (including, in various embodiments, one or more of the transportation devices 106 ) for wireless communication; the wheeled chassis on which the source pallet stacks 102, 104 are stacked (if self-propelled); the robotic arms 112, 114 and/or the respective chassis on which the robotic arms 112, 114 are mounted on the track 110; and robotically controlled tray handling end effectors 116,118. In various embodiments, the robotic elements are controlled by the control computer 128 based on input data (such as invoice, order, and/or manifest information) and input status information (such as inventory indicating which source pallet stacks contain which type and/or quantity of product). data) and control.

The source pallet stacks 102 , 104 are inserted into a gate or other access/control structure at the input 108 of the transporter 106 . Transporter 106 includes a device (stack mover) that moves source pallet stacks 102, 104 along rails 110 to optimize throughput and minimize robot displacement (e.g., by moving robot arms 112, 114 The distance and/or frequency that must be moved along track 110 in order to grab and place source trays on respective destination stacks is minimized). The source pallet stacks 102, 104 can be entered with pallets of different orientations/weights/and weight distributions. The system 100 uses force and moment control to operate the robotic arms 112, 114 to gently and firmly insert a thumb or other protrusion into a tray and plan its motion and tray trajectory so as not to collide with itself or the environment. In various embodiments, each robotic arm 112, 114 operates in a very compact space of about 2.5 m width and has a very small footprint. The robot utilizes its entire workspace and intelligently plans its motion to optimize its grip and/or efficiency (eg, time, collision avoidance, etc.) when unstacking source pallet stacks 102, 104. The robot recognizes the need to perform an orientation change and handles accordingly while avoiding obstacles. The robot moves to the correct output (destination pallet stack 120 , 122 ) corresponding to the correct customer, while coordinating with other robots on the track 110 . The robot then uses advanced force control and interaction with the environment to determine an appropriate placement strategy. Then start the cycle all over again.

In certain embodiments, the source pallet stacks 102, 104 are inserted by a robotic stack pusher system (not shown) onto the transporter 106 or into a gate or other access control structure corresponding to the input 108. System 100 includes a robotic stack pusher system to load a stack into a robotic workspace (eg, to an entry control structure corresponding to input 108 ). The control computer 128 controls the robotic stack pusher system to load a stack onto the transporter 106 in coordination with controlling the robotic arms 112 , 114 to pick items from and place items into stacks, such as pallet stacks 102 , 104 . In response to determining that a stock operation has been completed relative to a previous stack (e.g., a previous stack has been unloaded) and a gap in the workspace has been formed (e.g., by moving the previous stack to a stack return location), etc., Control computer 128 controls the robotic stack pusher system to load a stack into the robotic workspace of system 100 (eg, onto transporter 106 ).

In the example shown in FIG. 1A , system 100 includes a 3D camera 126 . In various embodiments, system 100 includes a plurality of 3D (or other) cameras, such as camera 126, and uses imagery and depth data generated by the cameras to generate workspaces and scenes such as the one shown in FIG. 1A /state) at least a 3D view of the relevant portion. In some embodiments, a camera such as camera 126 is used to identify the contents of trays in the source trays that make up a stack of trays, for example, by identifying the size, shape, packaging, and/or Marking, and/or identifying the shape, color, size or other attributes of the source stacking pallet itself and/or reading barcodes, QR codes, radio frequency tags or other image-based or non-image-based information on or from the pallet.

In various embodiments, image data generated by a camera such as camera 126 is used to move the robotic arm and end effector into close proximity to a pallet or two or more pallets to be gripped and picked from a source stack. In a position of the stack and/or positioning the pallet close to a destination where it will be placed, for example, at the top of a corresponding destination stack. In some embodiments, force control (as described more fully below) is used to complete the final phase of a pick/grab event and/or a put event.

While a single camera (e.g., camera 126) mounted to a wall in the workspace of system 100 is shown in FIG. 1A, in various embodiments, multiple cameras or other sensors, or a combination thereof, are statically mounted. in a workspace. Additionally or alternatively, one or more cameras or other sensors are mounted on or near each robotic arm 112, 114, such as on the arm itself and/or on the end effectors 116, 118, and/or on On a structure that travels with the robotic arms 112 , 114 as they move along the track 110 .

FIG. 1B is a block diagram illustrating a robot production line material preparation system according to the related art. In FIG. 1B , one example of a top view of a workspace in which the system 100 of FIG. 1A may operate is shown. In the example shown, the robotic arms 112, 114 move along a common track (e.g., track 110) as in FIG. Placed on a corresponding destination stack 142 in the destination stack assembly area on the opposite side of the track 110 from the source stack 140 and transporter 106 . In this example, a human worker manually feeds the source stack onto the transporter 106, but in some embodiments, a robotic worker performs all or part of that task, e.g., according to a programmatically generated plan to fulfill a set of orders each associated with a corresponding destination. In some embodiments, the system 100 includes a robotic stack pusher system (not shown) that loads a stack onto the transport device 106 . For example, the control computer 128 coordinately controls the robotic stack pusher system and the robotic arms 112, 114 to perform operations with respect to items picked/placed from/to the stack. In response to determining that a stocking operation has completed relative to a previous stack (e.g., a previous stack has been unloaded) and a gap has been formed in the workspace (e.g., by moving the previous stack to a stack return location), etc., Control computer 128 controls the robotic stack pusher system to load a stack into the robotic workspace of system 100 (eg, onto transporter 106 ). When destination stack 142 is complete, it is removed from the destination stack assembly area, as indicated by the arrow at the top of FIG. 1B (which corresponds to arrow 124 of FIG. 1A ).

Although in the examples shown in FIGS. 1A and 1B , the trays each contain only one type of item (e.g., items), in various embodiments and applications, source and destination trays with a mix of items can be processed To assemble the destination pallet stack, as disclosed herein. Similarly, although in the examples shown in FIGS. 1A and 1B , the source tray stacks each contain only trays of the same type and contents, in other embodiments and applications, the source tray stacks may include trays and/or items One of the types mixed. For example, the control computer 128 is provided with information indicating which types of pallets are located in which position in each source pallet stack, and uses that information along with a manifest or indication of the desired contents of each destination pallet stack other information to form the required destination pallet stacks by each picking the required pallets from a corresponding position on a source pallet stack and adding the pallets to a corresponding destination pallet.

While FIGS. 1A and 1B illustrate a system in which a robotic arm is controlled to pick an item or pallet from a source stack and place the item or stack to a destination location (e.g., destination stack 142), various embodiments include Items or pallets are placed onto stacks carried by transporter 106 . For example, certain embodiments implement a system of loading pallet stacks 102 , 104 .

2A is a block diagram illustrating a robotic production line material preparation system according to various embodiments. In the example shown, system 200 includes a robotic stack mover system 210 . System 200 uses robotic stack mover system 210 to move (e.g., along a path) pallet stacks 222a, 222b, and 222c (e.g., or a vehicle on which the pallet stacks are included or will be loaded) into position for a robotic arm 202 and 204 perform stocking operations, such as unstacking pallet stacks 222a, 222b, and 222c, or stacking pallets or placing items on pallets of the pallet stacks. In certain embodiments, the system 200 controls the robotic stack mover system 210 to move the pallet stacks 222a, 222b, and 222c into the workspaces of the robotic arms 202 and 204 (which may correspond, for example, to the ranges 206 and 208) or nearby locations. The robotic stack mover system 210 autonomously moves a pallet stack (or other vehicle) that is inserted into the robotic stack mover system 210 (eg, a predefined insertion location, between pusher units, etc.).

In various embodiments, robotic stack mover system 210 includes a drive unit 212 configured to move pallet stack 222a, such as by driving a mechanism to exert respective forces on pallet stacks 222a, 222b, and 222c , 222b and 222c. As an example, drive unit 212 includes a motor that is driven based at least in part on a determination that one of tray stacks 222a, 222b, and 222c is to be moved. The system 200 controls the motors through computer control, such as by a control computer 248 operatively connected to the robotic stack mover system 210 . In various embodiments, drive unit 212 further includes actuating one or more drive sprockets in response to the motor being driven. For example, the motor is connected to at least one of the one or more drive sprockets, and in response to the motor being driven, force is transmitted from the motor to the one or more drive sprockets. Alternatively or additionally, drive unit 212 includes a crank pulley or other mechanism to drive movement of a drive chain, belt, or the like.

In various embodiments, the robotic stack mover system 210 includes a tensioning unit 214 . The tensioning unit 214 is part of the drive system of the robotic stack mover system 210 and ensures that the drive system has sufficient tension. Additionally, tensioning unit 214 serves as a recirculation point for the drive system (eg, a drive chain is redirected and recirculated back to drive unit 212). In some embodiments, tensioning unit 214 includes one or more tensioning sprockets. At least one of the one or more tensioning sprockets is movably mounted in such a manner that the at least one tensioning sprocket changes a tension of the drive chain as the at least one tensioning sprocket moves. At least one tensioning sprocket movably mounted to the tensioning unit 214 is moved/adjusted via manual intervention, such as by a user, or via control of a computer system of the system. The tensioning unit is configured to adjust/enhance a tension in the drive chain of the system.

In various embodiments, the robotic stack mover system 210 includes a drive chain 217 . The drive chain 217 traverses the distance between the drive unit 212 and the tensioning unit 214 . Drive chain 217 receives force from drive unit 212 to cause drive chain 217 to move (eg, circulate within robotic stack mover system 210 ). In some embodiments, drive chain 217 is a double pitch chain having a profile that includes a hole or recess into which a tooth of a drive sprocket fits to engage the drive unit with the drive chain. 217. In some embodiments, drive chain 217 is a fabricated belt, such as a thermoplastic belt. Robotic stack mover system 210 further includes guide rails 216 configured to provide support for drive chain 217 to ensure drive chain 217 traverses a longitudinal direction between drive unit 212 and tensioning unit 214 . The longitudinal direction of the guide track 216 is parallel to (or similar to) the direction of the track 205 along which the robotic arms 202 and 204 travel (e.g., and on which the robotic arms 202 and 204 are mounted, such as via a robotic carrier). Traversing to pick and place items (eg, pallets, items from pallets, trucks, etc.).

In the example shown in Figure 2A, drive chain 217 includes a set of pusher units, such as pusher units 218a, 218b, 218c, and 218d. The pusher units of the set of pusher units are arranged at a predetermined distance along the drive chain 217 . The predetermined distance is determined based on a dimension of a pallet or stack of pallets. For example, the predetermined distance is 25% greater than the dimension (eg length) of a tray or tray stack. As another example, the predetermined distance is 10% greater than the dimension (eg, length) of a pallet or stack of pallets. As another example, the predetermined distance is 15% greater than the dimension (eg, length) of a tray or tray stack. As another example, the predetermined distance is 50% greater than the dimension (eg, length) of a tray or tray stack. In some embodiments, the predetermined distance between two adjacent pusher units (e.g., pusher unit 218a and pusher unit 218b) is large enough to allow a vehicle (e.g., a pallet stack, such as a pallet stack 222a, 222b or 222c) are inserted between two adjacent pusher units. For example, the predetermined distance is set equal to the sum of a dimension of the vehicle (eg, a length, a width, etc.) and a buffer interval (eg, 1 inch to 6 inches, etc.). In various embodiments, the predetermined distance between thruster units is configurable. For example, the system 200 or a human operator adjusts the spacing between thruster units by moving a subset of the thruster units and/or by removing a subset of the thruster units. The pusher unit is mounted on the drive chain 217 (eg, bolted to a bracket on a ring of the drive chain 217, etc.), or is integral with the drive chain 217 (such as by a spine or other structure).

In various embodiments, the pusher unit is configured to provide support for (eg, apply force to) a vehicle such as pallet stack 222a, 222b, or 222c to propel it. When the drive chain 217 is driven (eg, by a drive sprocket), the pusher units move respectively and cause the vehicle with which the pusher unit engages to move. The thruster unit can be made of various materials such as metals or alloys. The material of the thruster unit may be selected based on a stiffness and/or hardness to ensure that the thruster unit properly moves the vehicle (e.g., the thruster unit does not deform when engaged with the vehicle, or deforms less than a predetermined deformation threshold ). The pusher units have various profiles selected based at least in part on a configuration of an embodiment of the robotic stack mover system 210 . For example, as illustrated in FIG. 2A , pusher units 218a, 218b, 218c, and 218d are sufficiently large (eg, extending from a drive chain) to engage corresponding vehicles. As another example, pusher units 218a, 218b, 218c, and 218d include a chamfer at a proximal end (eg, the end connected to drive chain 217) of pusher units 218a, 218b, 218c, and 218d. The chamfer on the pusher unit is based on the size and geometry of the robotic stack mover system 210 (e.g., based on the geometry of the drive chain 217 when it is sufficiently tensioned between the drive unit 212 and the tensioning unit 214 ) to configure. For example, the chamfer is configured to ensure that a pusher unit has clearance at the drive unit 212 and tension unit 214 during recirculation of the drive chain 217 . As illustrated in FIG. 2A , the pusher unit 218d recirculates (eg, changes direction) at one end of the positioned tensioning unit 214 of the robotic stack mover system 210 . The chamfer ensures that sufficient clearance is provided between the pusher unit and adjacent pusher units, other rings in the drive chain 217, etc. as the pusher unit traverses the bend of the recirculation. In some embodiments, a pusher unit has a chamfer on a distal end (eg, the end opposite the end attached to the drive chain). For example, pusher unit 238b of robotic stack mover system 230 includes a chamfer at the distal and proximal ends. A chamfer on the distal end of a pusher unit facilitates insertion/removal of vehicles from a space between adjacent pusher units. For example, a chamfer on the distal end serves to guide the tray stack into and/or out of the space between adjacent pusher units. In various embodiments, the pusher unit includes a chamfer at the distal end, the proximal end, or both.

In various embodiments, the pallet stacks 220, 222a, 222b, 222c are manually advanced into an insertion zone. The insertion zone is located at the beginning of one of the paths traversed by the stack of pallets as the robotic stack mover system 210 moves it. For example, as illustrated in FIG. 2A , a pallet stack 220 is inserted at one end of a positioning drive unit 212 of a robotic stack mover system 210 . When a pusher unit is not within the insertion zone (eg, when the tray stack can be inserted between two adjacent pusher units), the tray stack 220 can be manually inserted into the insertion zone. In various embodiments, the insertion of the stack of trays is automated. For example, an insertion structure is inserted into a pallet stack at a time determined based on one or more of: (i) a position of at least one pusher unit (e.g., if a predetermined distance between pusher units spacing is known, then determine the relative position of the thruster unit), (ii) a determination that no thruster unit is within the insertion zone (e.g., to provide appropriate clearance for proper insertion), (iii) insert the drive chain 217, (iv) the order in which the pallet stack is unstacked (or filled by stacking the pallet, etc.), (v) a manifest corresponding to the particular pallet stack (e.g., on the pallet stack or a list of items to be loaded onto the pallet stack), (vi) a state of the robot arm 202 or 204, etc. As an example, the insertion structure includes a conveyor (eg, a conveyor belt) that moves stacks of pallets from a source location to the insertion zone. As another example, a robot is controlled to insert pallet stacks into the insertion zone. Immediately after a pallet stack is inserted into the robotic stack mover system 210, the robotic stack mover system autonomously advances the source pallet stack (e.g., pallet stacks 222a, 222b, and/or 222c) through the workspace (e.g., Mover system 210 or guide track 216). In various embodiments, the pallet stack is inserted at other locations where a space between adjacent pusher units is available (eg, no pallet stack occupies the space). For example, when robotic arm 202 unstacks tray stack 222a and/or robotic arm 204 unstacks tray stack 222c, tray stack 222b is inserted in its place. In some embodiments, the pallet stack is inserted at an interval comprising at least N pusher units, where N is an integer. For example, in certain implementations, pallet stacks occupy adjacent spaces between pusher units, such as shown with pallet stacks 222a, 222b, and/or 222c. As another example, in certain embodiments, every other set of pusher units is inserted into a pallet stack (such as to avoid adjacent pallet stacks), such as shown with pallet stack reserve 222d. Pallet stack stand-bys (e.g., spaces without pallet stacks inserted between adjacent pusher units) are implemented to provide clearance between pallet stacks and to ensure that robotic arms 202, 204 are picking items from pallet stacks (e.g., pallets) and place items on a pallet stack without colliding with adjacent pallet stacks. In some embodiments, if the system determines that a height of a particular pallet stack exceeds a predetermined height threshold, the system uses the pallet stack reserve.

In certain embodiments, pallet stacks 222a, 222b, and/or 222c are advanced by/by robotic stack mover system 210 under robotic control. For example, the speed and timing at which tray stacks 222a, 222b, and/or 222c are advanced by/through robotic stack mover system 210 is controlled to facilitate efficient grabbing of trays from tray stacks 222a, 222b, and/or 222c.

In the example shown, a single track (eg, track 205 ) is disposed along one long side of robotic stack mover system 210 . In this example, two robots, one robot including robot arm 202 and the other robot including robot arm 204 , are movably mounted on track 205 independently of each other. For example, each robotic arm 202 , 204 is mounted on a self-propelled chassis that slides along track 205 . In various embodiments, each robotic arm 202, 204 terminates with an end effector for performing a stocking operation. In an embodiment in which a pallet stack is stacked or unstacked, the robotic arm 202 or 204 terminates with a pallet handling end effector. In one implementation where objects are picked and placed from the vehicle, the robotic arms 202, 204 terminate with a suction-based end effector, a pincer end effector, or the like. The end effectors of robotic arm 202 and/or robotic arm 204 operate under robotic control. Based on a plan for picking/moving/placing items (e.g., pallets) and/or information about the workspace (such as range 206 of the robot arm 202 (e.g., workspace) or range 208 of the robot arm 204 (e.g., workspace) space) to determine robot control.

System 200 includes vision system 245 . In various embodiments, vision system 245 obtains information associated with the workspace of robotic arm 202 , robotic arm 204 , or the workspace of robotic stack mover system 210 and/or robotic stack mover system 230 . The vision system 245 is based, at least in part, by one or more sensors (e.g., a vision system such as a 2D/3D camera, a laser sensor, an infrared sensor, a sensor array, a weight sensors, etc.) to obtain information associated with the workspace. As an example, as illustrated in FIG. 2A , vision system 245 includes a camera 246 . Various other types of sensors may be implemented in conjunction with vision system 245 . In various embodiments, system 200 includes a plurality of 3D (or other) cameras, such as camera 246, and uses imagery and depth data generated by these cameras to generate workspaces and scenes such as the one shown in FIG. 2A /state) at least a 3D view of the relevant portion. In some embodiments, a camera, such as camera 246, is used to identify the contents of trays in the source trays that make up a stack of trays, for example, by identifying the size, shape, packaging, and/or Marking, and/or identifying the shape, color, size or other attributes of the source stacking pallet itself and/or reading barcodes, QR codes, radio frequency tags or other image-based or non-image-based information on or from the pallet.

In various embodiments, the image data generated by the vision system 245 (such as the camera 246) is used to move the robotic arm and end effector closer to a pallet or two or more pallets to be gripped and picked from a source stack. In one of the positions of the stack of pallets and/or positioning the pallet close to the destination where it will be placed, for example, at the top of a corresponding destination stack. In some embodiments, force control is used to complete the final phase of a pick/grab event and/or a put event.

While a single camera (e.g., camera 246) mounted to a wall in the workspace of system 200 is shown in FIG. 2A, in various embodiments, multiple cameras or other sensors, or a combination thereof, are statically mounted. in a workspace. Additionally or alternatively, one or more cameras or other sensors are mounted on or near each robotic arm 202, 204, such as on the arm itself, and/or on the end effector of the corresponding robotic arm, and/or Or mounted on a structure that travels with the robotic arms 202 , 204 as they move along the track 205 .

A robotic control system (e.g., a computer that controls the robotic arm 202, robotic arm 204, and/or robotic stack mover system 210, such as the control computer 248) such as in conjunction with grabbing or releasing a pallet and/or moving pallet stacks 222a, 222b , 222c (such as by driving the drive chain 217) to control the end effector to actuate the opening/closing of the end effector. The robotic control system controls the robotic stack mover system 210 and/or the robotic arms 202, 204 (e.g., end effectors) based at least in part on: (i) imagery of the workspace (e.g., obtained using the vision system 245 ), (ii) one or more sensors included in (or connected to) corresponding end effectors, and/or (iii) included in robotic stack mover system 210 (or robotic stack mover System 230) (or connected to the robotic stack mover system) one or more sensors. In some embodiments, the robotic control system controls the robot based at least in part on information about one or more pallet stacks (such as an identifier for a pallet stack, a manifest for a pallet stack, an order corresponding to a pallet stack, etc.) The robotic stack mover system 210 and/or the robotic arms 202, 204 (eg, end effectors). In certain embodiments, one or more sensors included in (or coupled to) a corresponding end effector are configured to: (i) obtain an indication of a gripping mechanism of the end effector ( For example, an active component) is in an open position or a closed position, (ii) obtain information indicative of the degree of opening of the gripping mechanism, (iii) obtain information indicative of the tray (or end effector relative to the tray) Information about when to be in a position where the end effector is controlled to align at least one side of the end effector (e.g., a passive component or a structure included on the passive component) with a tray (e.g., , being engaged by a hole in one side of a pallet), a recess, or a handle, (iv) obtaining information indicating when the pallet (or an end effector relative to the pallet) is in a position where , an end effector (e.g., a passive component or a structure included on a passive component) engages with a hole, recess, or handle included in a side of a tray, and/or (v) obtains an indication of whether the gripping mechanism is closed or Information that otherwise engages with the pallet.

The respective robotic arms 202, 204 operate fully autonomously simultaneously to pick pallets from the pallet stacks 222a, 222b, and/or 222c and place those pallets on the track 205 between the robotic stack mover system 210 and the pallet stacks 222a, 222b. and/or 222c on a destination pallet stack (such as destination pallet stack 240a, 240b and/or 240c) in a destination pallet stack assembly area on the opposite side. In various embodiments, a stack of destination pallets is assembled based on an invoice, manifest, order, or other information. For example, for each of a plurality of physical destinations (e.g., a retail store), by selecting pallets from respective pallet stacks 222a, 222b, and/or 222c and stacking those pallets in a corresponding destination pallet stack 240a, 240b, and/or 240c to form a destination stack associated with that destination (eg, an order placed according to the destination). Completed destination pallet stacks 240a, 240b, and/or 240c are removed from the destination pallet stack assembly area (as indicated by the arrows), for example, to place the completed destination pallet stacks on trucks, railcars, The container etc. is delivered to another destination, such as a retail store.

In various embodiments, the system 200 includes a robotic stack mover system 230, such as in conjunction with moving destination pallet stacks 240a, 240b, 240c (e.g., along one of the guide rails 236 of the robotic stack mover system 230 or A direction of the track 205 along which the robot arms 202, 204 traverse corresponds to a path). The robotic stack mover system 230 is implemented to provide a structure to move the destination pallet stacks 240a, 240b, 240c to facilitate moving the stacks within range of a particular robotic arm, or to allow insertion of additional destinations when other destination pallet stacks are complete stack of pallets. As an example, if pallet stack 222a includes a pallet containing items different from pallet stacks 222b, 222c, and system 200 determines that a set of such objects is to be placed on destination pallet stack 240c, system 200 controls robotic stack movement robot system 230 to move destination pallet stack 240c into range 206 of robotic arm 202 (e.g., this is because pallet stack 222a is within range of robotic arm 202, but in the example shown in FIG. 2A, robotic arm 202 Unable to reach destination pallet stack 240c).

With further reference to FIG. 2A, in the example shown, the system 200 includes a control computer 248 configured to communicate wirelessly with the robotic elements comprising the system 200, which in various embodiments include among One or more of: robotic stack mover system 210; robotic stack mover system 230; wheeled chassis (if self-propelled) on which pallet stacks 222a, 222b, and/or 222c are stacked; robotic arms 202, 204, and and/or the respective chassis on which the robotic arms 202 , 204 are mounted on rails 205 ; and the robotically controlled end effectors of the robotic arms 202 , 204 . In various embodiments, the robotic elements are controlled by the control computer 248 based on input data (such as invoice, order, and/or manifest information) and input status information (such as information about the workspace obtained by the vision system 245, such as instructions) Controls which source pallet stacks contain inventory data of which type and/or quantity of product).

The pallet stacks 222a, 222b, 222c are inserted into a gate or other access/control structure at the input of the robotic stack mover system 210 (eg, where the pallet stack 220 is inserted into the robotic stack mover system 210). The robotic stack mover system 210 moves the pallet stacks 222a, 222b, 222c along a path defined by one of the directions of the rails 205 (or guide rails 216) to optimize throughput and minimize robot displacement (e.g., By minimizing the distance and/or frequency with which the robotic arms 202, 204 must move along the track 205 in order to grab and place source trays on respective destination stacks). The tray stacks 222a, 222b, 222c can be entered with trays of different orientations/weights/and weight distributions. The system 200 uses force and moment control to operate the robotic arms 202, 204 to gently and firmly insert a thumb or other protrusion into a tray and plan its motion and tray trajectory so as not to collide with itself or the environment. In various embodiments, each robotic arm 202, 204 operates in a very compact space of approximately 2.5 m width and has a very small footprint. The robot (e.g., controlled via control computer 248) utilizes its entire workspace and intelligently plans its motion to optimize its grip and/or efficiency when unstacking pallet stacks 222a, 222b, and/or 222c ( For example, time, collision avoidance, etc.). The system 200 (eg, the control computer 248) recognizes the need to perform an orientation change and acts accordingly while avoiding obstacles. The robot moves to the correct output (destination pallet stack 240a, 240b, 240c) corresponding to the correct customer while coordinating with other robots on the track 205. The system 200 then uses advanced force control and interaction with the environment to determine an appropriate placement strategy. Then start the cycle all over again.

While system 200 illustrates an operator inserting stack 220 into the input of robotic stack mover system 210, in various embodiments, system 200 includes a robotic stack pusher system (not shown) that A stack (e.g., stack 220) is inserted (e.g., pushed) into an input of the robotic stack mover system 210 (which may also be referred to herein as a destination or final position of the robotic stack mover system or a One of the robotic stack mover systems payload introduction position). The input to the robotic stack mover system 210 is a transport structure (eg, a conveyor, etc.). In some embodiments, the robotic stack mover system advances stacks from a buffer strip (e.g., an area comprising a set of stacks to be loaded into the robotic stack mover system) to the input of the robotic stack mover system 210 . The control computer 248 controls both the robotic stack pusher system and the robotic stack mover system 210 . For example, the control computer 248 coordinately controls the robotic stack pusher system and the robotic stack mover system 210 to import stacks into the system and process the stacks (e.g., move the stacks through the robotic workspace and use the robotic arms 202, 204 to perform material preparation operations, etc.). The robotic stack mover system engages a stack and advances the stack to the input until the system determines that the stack is engaged by the robotic stack mover system 210 (such as by a pusher on the robotic stack mover system 210).

Robotic stack mover system 230 may be similar to robotic stack mover system 210 . For example, robotic stack mover system 230 includes drive unit 232, tensioning unit 234, guide rail 236, drive chain 237, and a set of pusher units, such as pusher units 238a, 238b, and 238c. In various embodiments, a robotic stack mover system includes a drive unit and tensioning unit disposed at opposite ends of a guide track. As illustrated using the robotic stack mover system 210 and the robotic stack mover system 230, the sides on which the drive unit and tensioning unit are respectively positioned may be interchangeable.

Although in the example shown in FIG. 2A, system 200 includes robotic stack mover system 210 and robotic stack mover system 230, in various embodiments, system 200 includes one robotic stack mover system, or system 200 is composed of The state is such that a robotic stack mover system is not included on the side of the robot that is opposite to the other side of the robot arm that includes a robotic stack mover system (e.g., system 200 includes robotic stack mover system 210 but does not include robotic stack mover system 230). An example of an implementation where the robotic stack mover system is not placed on the opposite side of a robotic arm includes being configured to obtain pallets from a transport structure (e.g., a conveyor, a chute, etc.) to stack pallets on a vehicle A system on (e.g., pallet stacks 222a, 222b, 222c, etc.), or configured to unstack pallets from a carrier (e.g., pallet stacks 222a, 222b, 222c, etc.) and place individual pallets in a transport structure A system that transports pallets to another area of a facility (eg, a robotic arm singulates pallets obtained from a carrier). In these embodiments, the system includes a transport structure located on the side of the robotic arms 202, 204 that is opposite the side of the robotic arms 202, 204 on which the robotic stack mover system 210 is disposed. Another example of an embodiment where the robotic stack mover system is not placed on the opposite side of a robotic arm includes where the robotic arm is controlled to self-feed (e.g., carry) the pallet or kit of items (e.g., items) A shelving system or a transport system stacked to the workspace of the robot arm. An example of such an implementation is illustrated in Figure 2C.

2B is a block diagram illustrating a robotic production line material preparation system according to various embodiments. In the example shown in FIG. 2B , the tray stacks are inserted on opposite sides of the track 205 . In various embodiments, robotic arms 202 and 204 are controlled to perform stocking operations relative to pallet stacks 222a, 222b, 222c, 254a, 254b, and/or 254c.

In various embodiments, robotic arms 202 and 204 are controlled to unstack items (eg, trays) relative to tray stacks 222a, 222b, 222c, 254a, 254b, and/or 254c. The robotic arm 202 picks pallets from the pallet stacks 222a, 222b, 222c, 254a, 254b, and/or 254c and places the pallets on a transport structure 252 that carries the destacked/unloaded pallets to a destination location (eg, another area of a facility). Robotic stack mover system 210 and robotic stack mover system 230 move pallet stacks 222a, 222b, and 222c and pallet stacks 254a, 254b, 254c, respectively, such as to facilitate unstacking operations (e.g., to optimize robotic arms 202, 204 for pallet stacking). The efficiency of the stack for unstacking, or providing space for inserting another pallet stack, etc.).

In various embodiments, robotic arms 202 and 204 are controlled to stack items (eg, pallets) relative to pallet stacks 222a, 222b, 222c, 254a, 254b, and/or 254c. Robotic arm 202 may pick up pallets delivered via transport structure 252 and place the pallets on pallet stacks 222a, 222b, 222c, 254a, 254b, and/or 254c. Pallet stacks 222a, 222b, 222c, 254a, 254b, and/or 254c are stacked according to a manifest, such as an order or invoice. Robotic stack mover system 210 and robotic stack mover system 230 move pallet stacks 222a, 222b, and 222c and pallet stacks 254a, 254b, 254c, respectively, such as to facilitate stack operations (e.g., to optimize robotic arms 202, 204 for pallet stacking). Efficiency for stacking, or providing space for inserting another pallet stack, etc.).

As illustrated in FIG. 2B , system 250 includes an autonomous tray stack insertion unit 256 . Autonomous pallet stack insertion unit 256 may be a transport structure, such as a conveyor. System 250 controls (eg, via control computer 248 ) autonomous tray stack insertion unit 256 to insert tray stacks into a space between adjacent pusher units. System 250 controls autonomous tray stack insertion based on a state of robotic stack mover system 230 or of one or more tray stacks (e.g., tray stacks 254a, 254b, and/or 254c) being engaged by robotic stack mover system 230 Unit 256. As an example, if system 250 includes a pallet stack insertion zone that includes autonomous pallet stack insertion unit 256, system 250 responds to having completed a stocking operation with respect to pallet stack 254c (which may be moved to a carrier return region) (such as a determination that a manifest or packing list of pallet stack 254c is complete or that the pallet stack has reached a threshold height) to determine the insertion of a new pallet stack.

According to various embodiments, the system 200 includes one or more robotic stack pusher systems (not shown) to insert a stack into the robotic stack mover systems 210 , 230 and/or insert a pallet into the transport structure 252 . While the examples illustrated in FIG. 2B include stacks 220 being inserted manually by an operator or a stack being inserted (e.g., automatically or robotically) via conveyor 255, system 200 includes a robotic stack pusher system(s) To insert the stack into one of the inputs of the robotic stack mover system 210 or one of the inputs of the robotic stack mover system 230 . In some embodiments, the robotic stack mover system advances stacks from a buffer zone (e.g., an area comprising a set of stacks to be loaded into the robotic stack mover system) to the robotic stack mover system 210 or the robot Input to the stack mover system 230 . The control computer 248 controls both the robotic stack pusher system and the robotic stack mover system 210 . For example, control computer 248 coordinately controls robotic stack pusher system and robotic stack mover system 210 and/or robotic stack mover system 230 to import stacks into the system and process stacks (e.g., move stacks through robotic work space and use the robotic arms 202, 204 to perform stock preparation operations, etc.). The robotic stack mover system engages a stack and pushes the stack to the input until the system determines that the stack has been moved by the robotic stack mover system 210 (such as by a pusher on the robotic stack mover system 210 (e.g., pusher unit 218a). etc.)) or the robotic stack mover system 230 (eg, pusher unit 238a, etc.) is engaged.

2C is a block diagram illustrating a robotic production line material preparation system according to various embodiments. In the example shown in FIG. 2C , system 275 includes robotic stack mover system 210 and a transport structure 280 . The robotic stack mover system 210 and a transport structure 280 are located on opposite sides of the track along which the robotic arms 202, 204 traverse. In various embodiments, robotic arms 202 and 204 are controlled to perform stocking operations relative to pallet stacks 222a, 222b, and/or 222c. For example, robotic arms 202, 204 pick up items (eg, items such as 282a, 282b, 282c, 282d, or 282e) from transport structure 280 and place the items on pallet stacks 222a, 222b, and/or 222c. As another example, the robotic arms 202, 204 pick up items from pallet stacks 222a, 222b, and/or 222c and place the items on a transport structure 280 that carries the items to a corresponding destination location.

Although in the examples shown in FIGS. 2A , 2B, and 2C each tray contains only one type of item, in various embodiments and applications, source and destination trays with a mix of items can be handled to assemble Destination pallet stacks, as disclosed herein. Similarly, while in the examples shown in FIGS. 2A , 2B, and 2C, the source tray stacks each contain only trays of the same type and contents, in other embodiments and applications, the source tray stacks may include both trays and / or a mix of one of the item types. For example, the control computer 248 is provided with information indicating which types of pallets are located in which position in each source pallet stack, and uses that information along with a manifest or indication of the desired contents of each destination pallet stack other information to form the required destination pallet stacks by each picking the required pallets from a corresponding position on a source pallet stack and adding the pallets to a corresponding destination pallet.

According to various embodiments, combining (eg, including) a system with a robotic stack mover system and a robotic stack mover system enables the system to automatically handle a group of vehicles (eg, stacks of pallets). The system detects when a specific stack/carrier is processed (e.g., when a stocking operation is complete with respect to the stack/carrier), and responds to detecting that the specific stack/carrier is processed (or expecting a specific/stack load tool processing is complete), the system controls the robotic stack mover system to move the stack/carrier to a stack/carrier return (e.g., an output), and the system controls the robotic stack pusher system to move a stack/carrier The vehicle is loaded onto one of the inputs (eg, the destination location) of the robotic stack mover system. The system then controls the robotic stack mover system to handle the stack/carrier (eg, perform a stock operation, or perform other pick/place operations relative to the stack or carrier). The system iteratively moves stacks/carriers through the workspace using the robotic stack mover system and inputs new stacks/carriers into the workspace using the robotic stack mover system (e.g., into the robotic stack mover system input) until there are no other stacks/carriers to process.

Figure 3A is a block diagram illustrating a stack pusher system according to various embodiments. In some embodiments, stack pusher system 300 is implemented in conjunction with system 100 of FIGS. 1A and 1B and/or system 200 of FIGS. 2A , 2B, and/or 2C. For example, stack pusher system 300 may be deployed in a system that includes a robotic stack mover system configured to engage one or more robotic arms relative to the stack (or relative to items) perform pick-and-place operations to move the stack through a workspace.

In the example shown, the stack pusher system 300 includes an actuation device 305 , one or more pusher structures 310 and a pusher mechanism 315 . The actuation device 305 is configured to move at least one pusher structure of the one or more pusher structures. For example, the actuation device 305 is configured to move at least one pusher in conjunction with moving (eg, configured) one or more pusher structures between a retracted state and an expanded state. Actuation device 305 is actuated (eg, controlled by a control computer) to cause one or more pusher structures 310 to move to an expanded state to move (eg, advance) stack 320 . Stack 320 may include one or more items, such as one or more items included in tray 325 . In some embodiments, the robotic stack mover system 300 moves the stack 320 to an input (eg, a destination location) of a robotic stack mover system. For example, a control computer controls the actuator 305 to move the one or more pusher structures 310 to an expanded state to insert the stack 320 into the input of a robotic stack mover system.

The example illustrated in FIG. 3A shows the robotic stack pusher system 300 in a retracted state (eg, retracted relative to a base plate or actuator device 305 ). In some embodiments, robotic stack pusher system 300 (eg, a control computer that controls robotic stack pusher system 300 ) controls propulsion mechanism 315 to drive actuator 305 in conjunction with moving one or more pusher structures 310 . Various pusher mechanisms are implemented to control/apply a force (eg, a linear force) to at least one of the one or more pusher structures 310 . In some embodiments, the linear force is applied by a linear axis whose position is controlled by the consistent force of the propulsion mechanism 315 . Examples of propulsion mechanisms include: (i) air or hydraulic pistons, (ii) linear actuators, and (iii) rack/pinion or other linear gear mechanisms driven by electric motors, etc. The robotic stack pusher system 300 is based on information obtained from one or more sensors included in a robotic workspace, such as based on a model of the workspace generated based on information obtained from a vision system. The propulsion mechanism 315 is controlled. For example, the system (eg, control computer) controls to actuate the actuation device 305 based on a state relative to a pick and place operation of a stacker/carrier handled by a robotic stack mover system. As another example, the system controls to be available based on a state of the robotic stack mover system, such as a vacant stack area/zone (e.g., a zone between two adjacent pusher units of the robotic stack mover system) One of the judgments, etc.) to actuate the actuator 305.

In some embodiments, the actuation device 305 includes a linear shaft or other mechanism to apply a linear force to at least one of the one or more pusher structures 310 . As an example, the linear shaft is operatively coupled to at least one pusher structure such that the at least one pusher structure receives a linear force and when the linear shaft is controlled to expand in a direction of the pusher structure toward the expanded state or in the direction of the pusher structure The at least one pusher structure is caused to move when the structure is retracted towards the retracted state in a reverse direction or when a force is applied.

Figure 3B is a block diagram illustrating a stack pusher system according to various embodiments. In the example shown, the actuation device 305 has been controlled to transition one or more pusher structures 310 to an expanded state. In response to driving advancement mechanism 315 and actuating a linear force via actuator device 305 , a linear force is applied to one or more pusher structures 310 , which in turn advance stack 320 .

According to various embodiments, a system includes a stack pusher system (eg, system 300 ) and a stack mover system (eg, system 400 ). The system coordinately controls the stack pusher system and the stack mover system to cause the stack pusher system to insert the stack/carrier into one of the inputs of the stack mover system, and to cause the stack mover system to move the stack/carrier through a stack mover system. The robot workspace to allow the robot arm to perform pick and place operations relative to the stacker/carrier. An example of a robotic stack mover system is described in more detail in conjunction with FIG. 4 .

Figure 4 is a block diagram illustrating one embodiment of a stack mover system. In the example shown in FIG. 4 , system 400 includes drive unit 410 and tension unit 420 . The driving unit includes a supporting structure 412 and a motor 414 . Motor 414 is configured to control the movement of drive chain 440 along the path defined by guide track 430 . In various embodiments, system 400 includes a set of rail feet, such as rail feet 432a, 432b, 432c, 432d, and/or 432e, to provide support for system 400 . The track feet may be bolted to a surface on which the system 400 is positioned, such as a factory floor.

In various embodiments, the track feet support two guide tracks side-by-side: a first guide track in which a portion of the drive chain 440 travels from the tensioning unit 420 to the drive unit 410 (e.g., a drive end); and A second guide track, wherein a portion of the driving chain 440 travels from the driving unit 410 to the tensioning unit 420 . As an example, a drive chain 440 is guided throughout the system 400 . For example, as illustrated in FIG. 4 , drive chain 440 enters the support structure of drive unit 410 or tensioning unit 420 to change the direction of drive chain 440 and recirculate drive chain within system 400 . In various embodiments, one guide track is used to engage a vehicle (eg, pull/push a vehicle along a path), and the other guide track is used to recirculate drive chain 440 . The guide rail may be a channel in which a drive chain 440 is positioned, and the pusher unit is mounted to the drive chain 440 and extended to the outside of one of the guide rails. Drive chain 440 includes a set of pusher units, such as 442a, 442b, 442c and 442d. As illustrated, the pusher unit 442d is moved into the support structure 412 of the drive unit 410 where the pusher unit 442 will recirculate to begin moving towards the tensioning unit 420 . Drive chain 440 is a double pitch chain to which pusher units 442a, 442b, 442c and 442d are mounted.

According to various embodiments, a pusher unit includes (or corresponds to) a drive bracket configured to mount to a drive chain. A drive bracket is mounted to the drive chain at a proximal end of the drive bracket. In various embodiments, the drive brackets include one or more chamfers to provide clearance for the drive brackets as they traverse the robotic stack mover system, or to facilitate insertion of a vehicle between two adjacent drive brackets (eg, to guide a vehicle into the space between two adjacent guide brackets).

In some embodiments, the pusher unit includes a drive bracket that includes one or more chamfers at a proximal end (eg, closer to the end of the stack), such as by mounting bolts to the drive chain. The chamfer is configured to provide clearance for the drive carriage as it moves within the robotic stack mover system (e.g., to avoid interference with a structure of the robotic stack mover system such as a drive sprocket or tension sprocket , or drive chain or adjacent drive bracket) collision). Chamfers can also be used to guide the stack/carrier during insertion of the stack/carrier into the robotic stack mover system.

In some embodiments, a robotic stack pusher system is deployed in connection with system 400 . The robotic stack mover system is robotically controlled to insert the stack/carrier into one input of the robotic stack mover system of system 400 . In the example shown, the input (eg, the destination location at which the vehicle is inserted by the robotic stack pusher system) corresponds to a region that is closer to the tensioning unit 420 than the foot 432b. As shown, the pusher units 442a , 442b , 442c advance from the end where the tensioning unit 420 is located to the end where the drive unit 410 is located. Thus, the robotic stack pusher system inserts the stack/carrier at the input end, and the robotic stack mover system of system 400 moves the stack/carrier through the workspace toward the end where drive unit 410 is located. As an example, when the stack/vehicle has been moved near the drive unit 410, a robotic arm(s) has completed a pick and place operation relative to the stack/vehicle and the stack/vehicle is moved to a return position.

In some embodiments, the system includes a stack mover system to move a payload(s), such as inserting the payload into a stack mover system. The payload is a floor level payload. Stack thruster systems are configured to move payloads of variable height or weight. For example, the payload includes a cart that includes a set of pallets stacked on it.

Figure 5A illustrates a diagram of a stack pusher in accordance with various embodiments. In some embodiments, robotic stack pusher system 500 includes a plurality of pusher structures. In the example shown, the robotic stack pusher system 500 includes a first pusher structure 515 and a stack engaging pusher structure 520 . The stack engaging pusher structure 520 (also referred to as a payload engaging pusher structure) engages the stack/carrier 525 and causes the stack/carrier to move, such as in a direction toward an input of a robotic stack mover system. The first pusher structure 515 and/or the state-engaged pusher structure are operatively connected to the base plate 505 . The robotic stack pusher system 500 is illustrated in a substantially retracted state. For example, robotic stack pusher system 500 is partially expanded (eg, relative to base plate 505 ) to provide an illustration of a nested configuration of first pusher structure 515 and stack-engaging pusher structure 520 . As illustrated in FIG. 5A , when in the retracted state, the first pusher structure 515 is partially enveloped by the stack engaging pusher structure 520 .

The system controls a drive mechanism (not shown) to drive/actuate the actuator 510 . The actuation device 510 includes a propulsion mechanism that applies a linear force to one or more of the first pusher structure 515 and the stack engaging pusher structure 520, thereby causing the robotic stack pusher system 500 to transition to an expanded state (eg, from a retracted state) or transition to a retracted state (eg, from an expanded state, such as after a stack has been successfully inserted into a robotic stack mover system). Examples of propulsion mechanisms include: (i) air or hydraulic pistons, (ii) linear actuators, and (iii) rack/pinion or other linear gear mechanisms driven by electric motors, etc. In the example shown, the actuating device 510 has a propulsion mechanism comprising an air or hydraulic piston. As an example, if the propulsion mechanism includes an air piston, actuating the drive mechanism causes the air piston to move in a linear direction substantially parallel to the direction in which the propeller structure expands or retracts. The air piston includes a linear shaft that applies a linear force to one or more of the first pusher structure 515 and the stack engaging pusher structure 520 when the air piston is actuated.

The robotic stack pusher system 500 is deployed in a warehouse or other facility where stacks/carriers are handled and pick and place operations are performed relative to the stacks/carriers. In some embodiments, the robotic stack pusher system 500 is bolted (or otherwise connected) to the facility via a base plate 505 (e.g., the base plate 505 contains through holes through which the robotic stack pusher system 500 through holes and bolted to ground). As another example, base plate 505 is made of a sufficiently rigid and/or heavy material (eg, steel) to enable deployment of robotic stack thruster system 500 without connection to the ground. The base plate 505 is sufficiently heavy to prevent the robotic stack pusher system 500 from vibrating and/or moving while being operated.

Figure 5B illustrates a diagram of a stack pusher in accordance with various embodiments. In the example shown, the robotic stack pusher system 500 is configured in an expanded state according to which the stack engaging pusher structure 520 expands relative to both the first pusher structure 515 and the base plate 505 , and the first pusher structure expands relative to the base plate 505 . When the actuator 510 of the robotic stack pusher system 500 is controlled to transition the robotic stack pusher system 500 to the expanded state (e.g., by engaging one of the pusher structure 520 and the first pusher structure 515 to the stack or both apply a linear force), the stack engages the pusher structure 520 in turn to apply a linear force to the stack/carrier 525.

The robotic stack mover system 500 transitions to a retracted state, such as in response to a determination that a stack/carrier has been successfully moved to a destination location (eg, to an input of the robotic stack mover system). In response to determining to transition the system to the retracted state, the system controls the actuating device 510 (eg, by controlling or otherwise actuating/driving compressed air) to apply a retracting force. For example, the actuation device 510 applies a retracting force (e.g., a linear force in a direction opposite the force used to expand the system) to one or both of the stack-engaging pusher structure 520 and the first pusher structure 515. force).

Figure 6A illustrates a diagram of a stack pusher in an expanded state, according to various embodiments. Figure 6B illustrates a diagram of a stack pusher in a retracted state, according to various embodiments. 6C is a diagram illustrating a front view of a stack pusher in a retracted state, according to various embodiments.

According to various embodiments, the stack pusher system 600 includes N cascaded stages (eg, pusher structures) that expand/retract according to robotic control. N is a positive integer. In certain embodiments, N cascaded stages are configured with bearing slides powered by a series of pulleys (e.g., pulleys 650a, 650b, etc.) and an air cylinder that allows N cascaded stages with approximately one N: 1 ratio retract and expand (eg, N cascade stages fully nested relative to each other).

In the example shown, the stack pusher system 600 includes a base plate 605 and a plurality of pusher structures (eg, a first pusher structure 620 and a stack engaging pusher structure 630 ). The plurality of pusher structures are controlled to expand or retract relative to the base plate 605, such as in connection with inserting a stack into a stack mover system. In certain embodiments, the stack thruster system is controlled to expand/retract multiple thrusters by controlling the application of a linear force by the actuation device 615 (e.g., an air piston controlled with compressed air, etc.). device structure. The plurality of thruster structures are supported (in part) by one or more wheels rolling on the floor of the warehouse in which the stacked thruster system 600 is deployed to facilitate a smooth and efficient transition between the expanded and retracted states . As an example, as illustrated in Figure 6A, a stack engaging pusher structure 630 is supported by wheels 635a, 635b. The stack engaging pusher structure 630 is further supported by support structures included in (or connected to) the first pusher structure 620, such as drawer slides 625a, 625b, configured to Movement between a retracted state and a desired state facilitates expansion/retraction of the stack engaging pusher structure 630 relative to the first pusher structure 620 . The pusher structure (e.g., stack engaging pusher structure 630) is supported by wheels and support structure (e.g., drawer slides) to facilitate being supported within its range of motion (e.g., between an expanded state and a retracted state). a mechanical stabilization system. Similarly, the first pusher structure 620 is supported by wheels or support structures (eg, wheels 627a, 627b). For example, the first pusher structure 620 is at least partially supported via drawer slides 610a, 610b included in (or connected to) the base plate 605 .

In the example shown, the actuation device 615 is connected to one or more of the pusher structures. For example, the actuating device 615 applies a linear force to the stack engaging pusher structure 630 in conjunction with controlling the expansion/retraction of the stack engaging pusher structure 630 . When the stack engaging pusher structure 630 expands to its expanded state relative to the first pusher structure 620, the stack engaging pusher structure 630 applies a linear force to the first pusher structure 620 to move the first pusher structure relative to the base plate 605. The pusher structure 620 is pulled to its expanded state.

In the example shown in Figure 6B, stack pusher system 600 is configured in a retracted state. Compared to FIG. 6A , the stack engaging pusher structure 630 completely (or nearly completely) covers the first pusher structure 620 . For example, a first pusher structure 620 nests within a stack of engaging pusher structures 630 . In the retracted state, both the stack engaging pusher structure 630 and the first pusher structure 620 are retracted relative to the base plate 605 . Thus, the stack pusher system 600 has a compact profile that is space efficient in the retracted state but facilitates control to move the stack in the workspace via controlled expansion of the pusher structure.

In the example shown in FIG. 6C , the stack pusher system 600 includes pulleys 631 a , 631 b , 631 c , and 631 d to which the pusher structure is connected and which move between the stack pusher system 600 in its expanded and retracted states. Transitions between states are facilitated while applying a linear force across the propeller structure.

Figure 6D illustrates a diagram of a stack pusher in accordance with various embodiments. In the example shown, the stack engaging pusher structure 630 is in an expanded state relative to the first pusher structure 620 . The pusher plate is at least partially supported by the wheels to facilitate a seamless movement of the pusher plate between the expanded state and the retracted state. For example, the first propeller structure 620 is supported by wheels 627a, 627b. The stack engaging pusher structure 630 is further supported by drawer slides 625a, 625b (also known as drawer slides or drawer runners). The drawer slides used to support the various pusher plates may be ball bearing drawer slides. In the example shown, the drawer slides 626a, 625b are mounted using a bottom mount. However, various other mounting techniques may be implemented, such as a side mount configuration or a center mount configuration. The drawer slides can have various expanded configurations based on the required stroke and/or maximum depth of the stack pusher system 600 (eg, the maximum allowable length for a particular pusher configuration). As an example, a drawer slide used to support the pusher structure provides a portion of the expansion (eg, an expansion of about 2/3 of the folded length of the drawer slide). As another example, a drawer slide used to support a pusher structure provides a full expansion (eg, an expansion of about 100% of the folded length of the drawer slide). A fully expanded drawer slide has at least 3 beams. As another example, the drawer slides used to support the pusher structure provide an over-extension. As an example, an overexpansion is an expansion greater than the folded length. As an example, an overexpansion is an expansion of 150% of the collapsed length of the drawer slide. Various other ranges of drawer slide extensions can be implemented.

According to various embodiments, a stack pusher system includes one or more sensors. The system uses information obtained from the one or more sensors in conjunction with controlling the stack pusher system, such as to determine the state of the stack pusher (e.g., an expanded state, a retracted state, an intermediate state, etc.), and to control the stack pusher Transition of the propeller to a desired state. One or more sensors obtain information about the position or state of a pusher structure, the amount of force applied by the actuator, the speed at which the pusher structure expands or retracts, a stack / Indicates whether the vehicle is engaged by one of the stack pusher systems (eg, by the stack engaging pusher structure). Examples of sensor types that may be implemented include cameras, infrared, force sensors, light sensors, proximity sensors, pressure sensors, or other position sensors.

Figure 6E illustrates a diagram of a stack pusher in accordance with various embodiments. The stack pusher system 600 includes one or more sensors for detecting a position or state of the pusher structure. In the example shown, stack pusher system 600 includes a shutter 655 . The shutter 655 is used to detect the position of at least one of the first pusher structures 620 . For example, the system uses the shutter 655 to determine whether the first pusher structure 620 is retracted. As another example, the system uses the shutter 655 to determine whether or not the first pusher structure 620 is expanded or by a degree to which the first pusher structure 620 is expanded. While the example shown includes only a single shutter 655, the stack pusher system 600 includes a plurality of sensors. For example, a shutter is disposed on the other side of the base plate 605 and/or the first pusher structure 620 .

Figure 7 illustrates a diagram of a stack pusher according to various embodiments. In the example shown, stack pusher system 700 moves the pusher structure from a starting position 750 to a final position (e.g., the distance between starting position 750 and final position corresponds to distance 760), such as to move stack 725 Move to a destination location (eg, an input to a robotic stack mover system).

Stack pusher system 700 includes a telescoping design in which a plurality of pusher structures move as the pusher structure moves from a starting position 750 to a final position (e.g., the distance between starting position 750 and final position corresponds to distance 760). The structure expands telescopically. The configuration of the stack pusher system 700 facilitates a reduced cost and space requirement for the stack pusher system 700 configured to extend a distance 760 corresponding to the stroke of the stack pusher system 700 . In the retracted state, stack pusher system 700 has a length corresponding to depth 765 . When the actuator 705 is actuated to apply a linear force to the pusher structure, the first pusher 715 and the stack engaging pusher 720 (eg, the pusher structure) telescopically expand toward the final position 755 .

In some embodiments, the required stroke of the stack pusher system 700 is greater than a maximum depth of the stack pusher system 700 . As illustrated in Figure 7, when configured in the retracted state, the required stroke corresponding to distance 760 is greater than the maximum depth of the stack pusher system (eg, depth 765). The telescoping or nested configuration of the pusher structure (eg, pusher structure 710, first pusher 715, etc.) enables the system 700 to expand a desired stroke while having only a maximum depth 765 when retracted.

Stack pusher system 700 includes one or more intermediate pusher structures (not shown) between first pusher 715 and stack engaging pusher structure 720 . For example, if the required stroke 760 exceeds twice the depth 765, the stack engaging pusher 700 includes one or more intermediate pusher structures. For example, if stack pusher system 700 has a maximum depth of depth 765 when retracted, each of first pusher 715 and stack engaging pusher 720 has a depth/depth less than or equal to depth 765 length. In certain embodiments, one or more intermediate pusher structures each have a depth/length less than or equal to depth 765 and are connected to first pusher 715 and stack engaging pusher 720 in a nested configuration, The one or more intermediate propeller structures are similarly telescopically expanded/retracted.

In some embodiments, starting location 750 corresponds to a location at which stack 770 is inserted into stack pusher system 700 . For example, as illustrated in FIG. 7 , a stack 770 is staged until inserted into the stack pusher system 700 . In some embodiments, the stack 770 is inserted into the stack pusher system 700 by a buffer transport structure. The buffer transport structure can move the stack 770 from a buffer/staging area to the input/insertion zone of the stack pusher system 700 .

Figure 8 illustrates a diagram of a stack pusher and a stack mover according to various embodiments. In the example shown, system 800 includes stack pusher system 850 deployed alongside stack mover system 810 . System 800 uses stack pusher system 850 to insert (eg, push) a stack into one of the inputs of stack mover system 810 . In response to determining that a stack is to be inserted into the input of stack mover system 810, system 800 uses stack mover system 810 to move the stack through the workspace, such as to one or more robotic arms (e.g., robotic arm 802 , 804).

In some embodiments, the stack pusher system 850 includes telescopically expanding one or more pusher structures (e.g., a stack engaging pusher structure, a first pusher structure, etc.), thereby moving the stack toward the stack The input of the device system 810 advances. The system 800 further includes a control computer 848 that controls the stack pusher system 850 . For example, the control computer 848 determines a plan for operating the stack pusher system 850 (eg, inserting/pushing a stack into an input of the stack mover system 810 ). Control computer 848 controls stack pusher system 850 to transition one or more pusher structures from a retracted state to an expanded state. In response to determining that a stack is inserted into the input of the stack mover system 810, the control computer 848 controls the stack pusher system 850 to retract one or more pusher structures to the retracted state. When the stack pusher system 850 is retracted, the next stack can be loaded to be inserted/pushed by the stack pusher system 850 .

In some embodiments, stacks to be loaded into the stack mover system 810 are buffered/assembled in the buffer zone 860 . Buffer zone 860 is disposed between stack pusher system 850 and stack mover system 810 . For example, the buffer zone 860 is positioned at a distance from the stack mover system 810 that is equal to or less than the expected or required travel of the stack pusher system 850 (e.g., the distance that the stack pusher system 850 will move the stack ). Buffer strip 860 includes a plurality of stacks queued for insertion into stack mover system 810 . In some embodiments, a buffer transport structure is included in the buffer zone 860 . As an example, the buffer transport structure is a robotically controlled transport. The buffer transport structure is configured to move the next stack into a position where the stack pusher system 810 will engage the stack (eg, one of the inputs of the stack pusher system 810 ). In some embodiments, the control computer 848 controls the buffer transport structure to advance the next stack to a position where the stack pusher system 810 will engage the next stack. For example, the control computer 848 controls the buffer transport structure in coordination with the stack pusher system 850 in conjunction with the insertion of the stack into the stack mover system 810 .

In some embodiments, system 800 includes gating structure 855 . Gating structure 855 is part of stack pusher system 850, buffer strip 860 (eg, part of a buffer transport structure), or a stand-alone device. The gating structure 855 is configured to regulate the insertion of stacks into the stack mover system 810 . Gating structure 855 includes, for example, a gate that is robotically controlled, such as by control computer 848 . A gating structure 855 is disposed between the buffer strip 860 and the stack mover system 810 to prevent/impede stacks from entering the input of the stack mover system 810 when the gates are closed and to allow stacks to be inserted into the stack mover system when the gates are open 810 input. In some embodiments, the gating structure 855 is positioned between the stack pusher system 850 and the buffer zone 860, or the system 800 includes a plurality of gating structures—one gating structure positioned between the stack pusher system 850 and the buffer zone 860. belt 860, and another gating structure is disposed between the buffer belt 860 and the stack mover system 810.

The control computer 848 controls the actuation of the gate to move the gate to an open position or a closed position. In certain embodiments, the control computer 848 controls the gating structure 855 (e.g., actuation of gates) in coordination with the stacker system 810 or otherwise based on information about the workspace or status of the stacker system 810 . Gating structure 855 includes one or more sensors (such as light sensors or cameras) for detecting one or more of: whether a stack is loaded into buffer strip 860, buffer strip A queue of the stack in 860, a state of the gate (for example, whether the gate is open or closed), etc. Control computer 848 based at least in part on information obtained from one or more sensors of gating structure 855 or one or more sensors disposed elsewhere in system 800 (e.g., a vision system of system 800) Control gating structure 855 . For example, control computer 848 controls gating structure 855 based at least in part on one or more of: (i) a determination of whether an input to stacker mover system 810 is vacant, (ii) a stack A determination is being output from the stack mover system 810 (e.g., after the robotic arms 802, 804 have completed a stocking operation relative to the stack), and (iii) the robotic arm in the workspace has completed A determination of an operation in which the mover system 810 moves a stack through the workspace (eg, a robotic arm has completed a stocking operation to unload or load a stack of pallets). Various other factors may be used in conjunction with controlling the gating structure 855 to open/close the gate.

System 800 uses robotic stack mover system 810 to move (e.g., along a path) pallet stacks 822a, 822b, and 822c (e.g., or a vehicle in which the pallet stacks are included or will be loaded) into position for the robot Arms 802 and 804 perform stocking operations, such as unstacking pallet stacks 822a, 822b, and 822c, or stacking pallets or placing items on pallets in a pallet stack. In certain embodiments, system 800 controls robotic stack mover system 810 to move pallet stacks 822a, 822b, and 822c into or near the workspaces of robotic arms 802 and 804 (which may correspond, for example, to ranges 806 and 808) the respective positions. The robotic stack mover system 810 autonomously moves a pallet stack (or other vehicle) that is inserted into the robotic stack mover system 810 (eg, a predefined insertion location, between pusher units, etc.). The stack mover system 810 is controlled in coordination with the stack pusher system 850 or a buffer transport device and/or gate structure 855 in another buffer zone 860 .

In various embodiments, the robotic stack mover system 810 includes a drive unit 812 configured to move tray stacks 822a, 822a, 822c, such as by driving a mechanism to apply respective forces to tray stacks 822a, 822b, and 822c. 822b and 822c. As an example, drive unit 812 includes a motor that is driven based at least in part on a determination that one of tray stacks 822a, 822b, and 822c is to be moved. The system 800 controls the motors through computer control, such as by a control computer 848 operatively connected to the robotic stack mover system 810 . The drive unit 812 may be similar or identical to the drive unit 212 of the system 200 of FIG. 2A .

In various embodiments, the robotic stack mover system 810 includes a tensioning unit 814 . The tensioning unit 814 is part of the drive system of the robotic stack mover system 810 and ensures that the drive system has sufficient tension. Additionally, tensioning unit 814 serves as a recirculation point for the drive system (eg, a drive chain is redirected and recirculated back to drive unit 812). The tensioning unit is configured to adjust/enhance a tension in the drive chain of the system. Tensioning unit 814 may be similar or identical to tensioning unit 214 of system 200 of FIG. 2A .

In various embodiments, the robotic stack mover system 810 includes a drive chain 817 . The drive chain 817 traverses the distance between the drive unit 812 and the tensioning unit 814 . Drive chain 817 receives force from drive unit 812 to cause drive chain 817 to move (eg, circulate within robotic stack mover system 810 ). In some embodiments, drive chain 817 is a double pitch chain having a profile that includes a hole or recess into which a tooth of a drive sprocket fits to engage the drive unit with the drive chain 817. Drive chain 817 may be similar or identical to drive chain 217 of system 200 of FIG. 2A . The robotic stack mover system 810 further includes guide rails 816 configured to provide support for the drive chain 817 to ensure that the drive chain 817 traverses a longitudinal direction between the drive unit 812 and the tensioning unit 814 . The longitudinal direction of the guide track 816 is parallel to (or similar to) the direction of the track 805 along which the robotic arms 802 and 804 travel (e.g., and on which the robotic arms 802 and 804 are mounted, such as via a robotic carrier). Traversing to pick and place items (eg, pallets, items from pallets, trucks, etc.).

In the example shown in FIG. 8 , drive chain 817 includes a set of pusher units, such as pusher unit 818 . The pusher units of the set of pusher units are positioned at a predetermined distance along the drive chain 817 . The predetermined distance is determined based on a dimension of a pallet or stack of pallets. For example, the predetermined distance is 25% greater than the dimension (eg length) of a tray or tray stack. As another example, the predetermined distance is 10% greater than the dimension (eg, length) of a pallet or stack of pallets. As another example, the predetermined distance is 15% greater than the dimension (eg, length) of a tray or tray stack. As another example, the predetermined distance is 50% greater than the dimension (eg, length) of a tray or tray stack. In some embodiments, the predetermined distance between two adjacent pusher units (e.g., pusher unit 818) is large enough to allow a vehicle (e.g., a pallet stack, such as pallet stack 822a, 822b, or 822c) ) is inserted between two adjacent thruster units. For example, the predetermined distance is set equal to the sum of a dimension of the vehicle (eg, a length, a width, etc.) and a buffer interval (eg, 1 inch to 6 inches, etc.). In various embodiments, the predetermined distance between thruster units is configurable. For example, the system 800 or a human operator can adjust the spacing between thruster units by moving a subset of the thruster units and/or by removing a subset of the thruster units. The pusher unit is mounted on the drive chain 817 (eg, bolted to a bracket on a ring of the drive chain 817, etc.), or integral with the drive chain 817 (such as by a spine or other structure).

In various embodiments, the pusher unit is configured to provide support (eg, apply force to the vehicle) for propelling a vehicle such as pallet stack 822a, 822b, or 822c. When the drive chain 817 is driven (eg, by a drive sprocket), the pusher units move respectively and cause the vehicle with which the pusher unit engages to move. A pusher unit (eg, pusher unit 818) may be similar or identical to pusher units 218a, 218b, 218c, and 218d of system 200 of FIG. 2A. The pusher unit may have various profiles selected based at least in part on a configuration of an embodiment of the robotic stack mover system 810 .

In various embodiments, the pallet stacks 822a, 822b, 822c may be manually advanced into an insertion zone. The insertion zone is located at the beginning of one of the paths traversed by the stack of pallets as the robotic stack mover system 210 moves it. For example, as illustrated in FIG. 2A , a pallet stack 220 is inserted at one end of a positioning drive unit 212 of a robotic stack mover system 210 . In various embodiments, the insertion of the stack of trays is automated. By way of example, the insertion zone corresponds to the input where the stack is inserted/advanced by the stack pusher system 850 . For example, the stack pusher system 850 inserts the tray stack at a time determined based on one or more of: (i) a position of at least one pusher unit (e.g., if there is a gap between the pusher units a predetermined spacing is known, then determine the relative position of the thruster unit), (ii) a determination that no thruster unit is within the insertion zone (e.g., to provide appropriate clearance for proper insertion), (iii) insertion The speed of the drive chain 817, (iv) the order in which the pallet stack is unstacked (or filled by stacking pallets, etc.), (v) a manifest corresponding to a particular pallet stack (e.g., (a list of items on or to be loaded onto the pallet stack), (vi) a state of the robot arm 802 or 804, etc. Immediately after a pallet stack is inserted into robotic stack mover system 810, the robotic stack mover system autonomously advances the source pallet stack (e.g., pallet stacks 822a, 822b, and/or 822c) through the workspace (e.g., Mover system 810 or guide track 816). In various embodiments, the pallet stack is inserted at other locations where a space between adjacent pusher units is available (eg, no pallet stack occupies the space). For example, when robotic arm 802 unstacks tray stack 822a and/or robotic arm 804 unstacks tray stack 822c, tray stack 822b is inserted in its place. In some embodiments, the pallet stack is inserted at an interval comprising at least N pusher units, where N is an integer. For example, in certain implementations, stacks of trays occupy adjacent spaces between pusher units, such as shown with stacks of trays 822a, 822b, and/or 822c. As another example, in certain embodiments, every other set of pusher units is inserted into a pallet stack (such as to avoid adjacent pallet stacks), such as shown with pallet stack reserve 822d. Pallet stack stand-bys (e.g., spaces without pallet stacks interposed between adjacent pusher units) are implemented to provide clearance between pallet stacks and to ensure that robotic arms 802, 804 are picking items from pallet stacks (e.g., pallets) and place items on a pallet stack without colliding with adjacent pallet stacks. In some embodiments, if the system determines that a height of a particular pallet stack exceeds a predetermined height threshold, the system uses the pallet stack reserve.

In certain embodiments, pallet stacks 822a, 822b, and/or 822c are advanced by/by robotic stack mover system 810 under robotic control. For example, the speed and timing at which pallet stacks 822a, 822b, and/or 822c are advanced by/through robotic stack mover system 810 is controlled (e.g., by control computer 848) to facilitate movement from pallet stacks 822a, 822b and / or 822c for efficient gripping of pallets.

In the example shown, a single track is positioned along one long side of the robotic stack mover system 810 . In this example, two robots, one robot including robot arm 802 and the other robot including robot arm 804 , are movably mounted on track 805 independently of each other. For example, each robotic arm 802 , 804 is mounted on a self-propelled chassis that slides along track 805 . In various embodiments, each robotic arm 802, 804 terminates with an end effector for performing a stocking operation. In an embodiment in which stacks of pallets are stacked or unstacked, the robotic arm 802 or 804 terminates with a pallet handling end effector. In one implementation where objects are picked and placed from the vehicle, the robotic arms 202, 204 terminate with a suction-based end effector, a pincer end effector, or the like. In some embodiments, the robotic arm 202, 204 terminates with a multimodal end effector (eg, has the multimodal end effector mounted thereon). The multi-mode end effector includes a first gripping mechanism and a second gripping mechanism. The first gripping mechanism is configured to grip the object using a suction-based end effector. The second gripper mechanism is configured to grip the object using a set of gripper arms. The end effectors of robotic arm 802 and/or robotic arm 804 operate under robotic control. Based on a plan for picking/moving/placing items (e.g., pallets) and/or information about the workspace (such as range 806 of the robot arm 802 (e.g., workspace) or range 808 of the robot arm 804 (e.g., workspace) space) to determine robot control.

System 800 includes one or more sensors, including vision system 845 . In various embodiments, the vision system 845 is provided with the robotic arm 802, the workspace of the robotic arm 804 or the robotic stack mover system 210, the robotic stack mover system 810, the stack pusher system 850, the buffer zone 860, and a buffer transport Information associated with one or more of the device's workspaces, the buffer transport moves stacks in the buffer strip 860 . The vision system 845 is based, at least in part, by one or more sensors (e.g., a vision system such as a 2D/3D camera, a laser sensor, an infrared sensor, a sensor array, a weight sensors, etc.) to obtain information associated with the workspace. Various other types of sensors may be implemented in conjunction with vision system 845 . In various embodiments, system 800 includes a plurality of 3D (or other) cameras, such as camera 846, and uses the imagery and depth data produced by these cameras to generate workspaces and scenes, such as the one shown in FIG. /state) at least a 3D view of the relevant portion. In some embodiments, a camera such as camera 846 is used to identify the contents of trays in the source trays that make up a tray stack, for example, by identifying the size, shape, packaging, and/or Marking, and/or identifying the shape, color, size or other attributes of the source stacking pallet itself and/or reading barcodes, QR codes, radio frequency tags or other image-based or non-image-based information on or from the pallet.

In various embodiments, image data generated by vision system 845 (such as camera 846) is used to move the robotic arm and end effector closer to a pallet or two or more pallets to be gripped and picked from a source stack. In one of the positions of the stack of pallets and/or positioning the pallet close to the destination where it will be placed, for example, at the top of a corresponding destination stack. In some embodiments, force control is used to accomplish the final phase of a pick/grab event and/or a put event.

While a single camera (e.g., camera 846) mounted to a wall in the workspace of system 800 is shown in FIG. 8, in various embodiments, multiple cameras or other sensors, or a combination thereof, may be statically installed in a working space. Additionally or alternatively, one or more cameras or other sensors are mounted on or near each robotic arm 802, 804, such as on the arm itself, and/or on the end effector of the corresponding robotic arm, on Mounted on or around the stack pusher system 850 , the stack mover system 810 , and/or the buffer zone 860 on a structure that the robotic arms 802 , 804 travel with as they move along the track 205 .

A robotic control system (e.g., a computer that controls robotic arm 802, robotic arm 804, and/or robotic stack mover system 810, such as control computer 848) such as in conjunction with grabbing or releasing a pallet and/or moving pallet stacks 822a, 822b , 822c (such as by driving the drive chain 817) to control the end effector to actuate the opening/closing of the end effector. The robot control system controls the stack pusher system 850 to move (eg, push) the stack to the input of the stack mover system 810 . The robotic control system controls the stack pusher system 850, the robotic stack mover system 810, and/or the robotic arms 802, 804 (e.g., end effectors) based at least in part on: (i) image data of the workspace (e.g., , obtained using vision system 845), (ii) one or more sensors included in (or connected to) corresponding end effectors, (iii) included in robotic stack mover system 810 (or robot one or more sensors in (or connected to) the stack mover system 230), (iv) one or more sensors included in the stack mover system 850, and/or (v) Include one or more sensors in the buffer zone 860 . In some embodiments, the robotic control system controls the robot based at least in part on information about one or more pallet stacks (such as an identifier for a pallet stack, a manifest for a pallet stack, an order corresponding to a pallet stack, etc.) The robotic stack mover system 810 and/or the robotic arms 802, 804 (eg, end effectors). In certain embodiments, one or more sensors included in (or coupled to) a corresponding end effector are configured to: (i) obtain an indication of a gripping mechanism of the end effector ( For example, an active component) is in an open position or a closed position, (ii) obtain information indicative of the degree of opening of the gripping mechanism, (iii) obtain information indicative of the tray (or end effector relative to the tray) Information about when to be in a position where the end effector is controlled to align at least one side of the end effector (e.g., a passive component or a structure included on the passive component) with a tray (e.g., , being engaged by a hole in one side of a pallet), a recess, or a handle, (iv) obtaining information indicating when the pallet (or an end effector relative to the pallet) is in a position where , an end effector (e.g., a passive component or a structure included on a passive component) engages with a hole, recess, or handle included in a side of a tray, and/or (v) obtains an indication of whether the gripping mechanism is closed or Information that otherwise engages the pallet.

According to various embodiments, the robotic control system coordinately controls the stack pusher system 850, the stack mover system 810, and the robotic arms 802, 804. For example, the robotic control system determines a high-level plan to perform stocking operations relative to one or more stacks, and a lower-level plan to control the stack pusher system 850, the stack mover system 810, and the robotic arms 802, 804. Each (if applicable) to perform the tasks of the high-level plan. The robotic system is then controlled to implement the lower-level plan in a coordinated (eg, synchronous or simultaneous) manner to achieve the tasks of the higher-level plan.

The respective robotic arms 802, 804 operate fully autonomously simultaneously to pick pallets from the pallet stacks 822a, 822b, and/or 822c and place those pallets on the track 805 between the robotic stack mover system 810 and the pallet stacks 822a, 822b. and/or 822c on a destination pallet stack (such as destination pallet stacks 840a, 840b, and/or 840c) in a destination pallet stack assembly area on the opposite side. In various embodiments, a stack of destination pallets is assembled based on an invoice, manifest, order, or other information. For example, for each of a plurality of physical destinations (e.g., a retail store), by selecting pallets from respective pallet stacks 822a, 822b, and/or 822c and stacking those pallets in a corresponding destination pallet stack 840a, 840b, and/or 840c to form a destination stack associated with that destination (eg, an order placed according to the destination). Completed destination pallet stacks 840a, 840b, and/or 840c are removed from the destination pallet stack assembly area (as indicated by the arrows), for example, to place the completed destination pallet stacks on trucks, railcars, The container etc. is delivered to another destination, such as a retail store.

In various embodiments, the system 800 includes a robotic stack mover system 810, such as in conjunction with moving destination pallet stacks 840a, 840b, 840c (e.g., along one of the guide rails 816 with the robotic stack mover system 810 or A direction of the track 805 along which the robot arms 802, 804 traverse corresponds to a path). Robotic stack mover system 830 is implemented to provide a structure to move destination pallet stacks 840a, 840b, 840c to facilitate moving the stacks within range of a particular robotic arm, or to allow insertion of additional destinations when other destination pallet stacks are complete stack of pallets. As an example, if pallet stack 822a includes a pallet containing items different from pallet stacks 822b, 822c, and system 800 determines that a set of such objects is to be placed on destination pallet stack 840c, system 800 controls robotic stack movement robot system 810 to move destination pallet stack 840c into range 806 of robotic arm 802 (e.g., this is because pallet stack 822a is within range of robotic arm 802, but in the example shown in FIG. Unable to reach destination pallet stack 840c).

With further reference to FIG. 8, in the example shown, the system 800 includes a control computer 848 configured to communicate wirelessly with the robotic elements comprising the system 800, which in various embodiments include among One or more of: robotic stack mover system 810; robotic stack pusher system 850; wheeled chassis upon which pallet stacks 822a, 822b, and/or 822c are stacked (if self-propelled); robotic arms 802, 804, and and/or the respective chassis on which the robotic arms 802 , 804 are mounted on rails 805 ; and the robotically controlled end effectors of the robotic arms 802 , 804 . In various embodiments, the robotic elements are controlled by the control computer 848 based on input data (such as invoice, order, and/or manifest information) and input status information (such as information about the workspace obtained by the vision system 845, such as instructions) Controls which source pallet stacks contain inventory data of which type and/or quantity of product).

The tray stacks 822a, 822b, 822c are inserted into a gate or other access/control structure at the input of the robotic stack mover system 810 (eg, where the tray stack 220 is inserted into the robotic stack mover system 810). The robotic stack mover system 810 moves the pallet stacks 822a, 822b, 822c along a path defined by one of the directions of the track 805 (or guide track 816) to optimize throughput and minimize robot displacement (e.g., By minimizing the distance and/or frequency with which the robotic arms 802, 804 must move along the track 805 in order to grab and place source trays on respective destination stacks). The pallet stacks 822a, 822b, 822c can be entered with pallets of different orientations/weights/and weight distributions. The system 800 uses force and moment control to operate the robotic arms 802, 804 to gently and firmly insert a thumb or other protrusion into a tray and plan its motion and tray trajectory so as not to collide with itself or the environment. In various embodiments, each robotic arm 802, 804 operates in a very compact space of about 2.5 m width and has a very small footprint. The robot (e.g., controlled via control computer 848) utilizes its entire workspace and intelligently plans its motion to optimize its grip and/or efficiency when unstacking pallet stacks 822a, 822b, 822c (e.g., time, collision avoidance, etc.). The system 800 (eg, the control computer 848) recognizes the need to perform an orientation change and acts accordingly while avoiding obstacles. The robot moves to the correct output (destination pallet stack 840a, 840b, 840c) corresponding to the correct customer while coordinating with other robots on track 805. System 800 then uses advanced force control and interaction with the environment to determine an appropriate placement strategy. Then start the cycle all over again.

Figure 9A is a state diagram illustrating one embodiment of an automated process for moving a stack of pallets. In various embodiments, processes according to state diagram 900 are executed by a control computer, such as control computer 848 of FIG. 8 . In the example shown, a plan state, program, and/or module 902 generates and dynamically updates a plan to insert a carrier (e.g., a stack of pallets), such as by using robotic tools as disclosed herein to a robotic stack mover system to move carriers (eg, source pallet stacks, destination pallet stacks, etc.) according to a set of orders, invoices, manifests, etc. The planning status, program, and/or module 902 receives feedback indicating which destination pallet stacks have been completed, which source pallet stacks have been moved into the workspace, and/or can be used for continuous updates to move pallet stacks or cause pallet stacks to Additional status and background information for planning to return to a designated return area or insert a new pallet stack into the robotic stack mover system. In state 904, a program decision to control a given robotic tool (e.g., robotic stack mover system 810 in the example shown in FIG. One current overall plan moves from a source of pallet stacks to a set of one or more carriers under a specific location along a path along a guide track of a robotic stack mover system. For example, a robot (or system, such as a control computer 848) inserts a new stack of pallets into the system (e.g., the system controls a stack pusher system to insert a new stack into the stack mover system, or the system can coordinate Control a buffer transporter and stack pusher system to insert new stacks), or advance a pallet stack already in the system (e.g., move the pallet stack further along a path defined by the robotic stack mover system, etc.). The system enters state 906, where a strategy and plan is developed that is determined to engage a pallet stack, insert a pallet stack, and/or move a pallet stack within the workspace, and/or begin moving the pallet stack toward The destination location moves. The system enters state 908 where the system controls the robotic stack mover system to move the pallet stack. Once a pallet stack that has been inserted/moved to a determined destination location has been grasped, the system enters state 910, where the system controls a robotic arm(s) to perform a stocking operation relative to the pallet stack (e.g. unstacking, or stacking pallets on carriers, etc.). A system (such as the control computer 848) controls a robotic arm(s) to move a pallet along a planned (and if necessary, dynamically adapted) trajectory near the destination stack, e.g., hovering over the destination stack A location and/or a location or structure on which a pallet is placed. Once it is determined that the stocking operation has been safely performed, the system determines that pallet stacking is complete (e.g., stacking is complete, or unstacking of pallet stacks is complete) and re-enters state, procedure, and/or module 902, wherein the determination will be, for example, based on The overall planning information received from the planning state, program, and/or module 902 picks the next set of one or more carriers (e.g., pallet stacks) from a corresponding source and moves the next set of one or more carriers to A corresponding destination location (eg, a path along the workspace of the robotic stack mover system). In various embodiments, a robotic system as disclosed herein continues to loop through the states, procedures, and/or modules 902, 904, 906, 908, and 910 of FIG. 9A until all destination stacks have been assembled.

Figure 9B is a state diagram illustrating one embodiment of an automated process for assembling a stack of pallets. In various embodiments, processing according to state diagram 915 is performed by a control computer, such as control computer 848 of FIG. 8 . In the example shown, a planning state, program and/or module 917 generates and dynamically updates a plan to assemble output pallet stacks by using robotic tools as disclosed herein, such as based on a set of orders, Invoice manifests, etc. pick pallets from homogeneous or non-homogeneous source pallet stacks and form destination stacks each having one or more types of pallets, etc. Planning status, program and/or module 917 receives feedback indicating which destination pallet stacks have been completed, which source pallet stacks have been moved into the workspace, and/or can be used for continuous updates for picking and placing (stacking) pallets Additional status and background information for planning to assemble the destination stack. In state 919, a program decision to control a given robotic tool (e.g., in the example shown in FIG. And/or module 917 receives a current overall plan to move from a source stack to a set of one or more pallets below a destination stack. For example, the robot (or system, such as the control computer 848) determines that one, two, or more pallets will be grabbed from a source stack to add those pallets to the destination stack (or initiate a new destination stack). stack). The robot enters state 921 in which a strategy and plan is developed that is determined to do one or more of the following: move into position for grabbing a pallet, grab a pallet, and/or begin Wait for the pallet to move towards the destination stacking location; and the robot moves into position and grabs the pallet. Once the pallet has been grasped, the robot (or system, such as the control computer 848) enters state 923, where the pallet is moved along a planned (and dynamically adapted if necessary) trajectory near the destination stack, e.g., hovering A location above the destination stack and/or a location or structure on which the destination stack will be formed. In state 925, the robot places the pallet on the destination stack. In some embodiments, state 925 includes manipulation under force control to verify that the pallet is securely placed on the destination stack, for example, by: moving the pallet forward and backward (or side to side, if applicable ) move (or attempt to move) to ensure that any interconnect structures are aligned and slotted well, such as tabs on the bottom of the tray are placed to fit into corresponding recesses in the sidewall of the tray on which the tray rests. Once it is determined that the pallet has been safely placed, the robot releases the pallet and re-enters state 919 where it is determined to pick and move from a corresponding source stack, e.g. To a set of one or more pallets below a corresponding destination stack. In various embodiments, a robotic system as disclosed herein continues to loop through states 919, 921, 923, and 925 of FIG. 9B until all destination stacks have been assembled.

Figure 10A is a flowchart illustrating one embodiment of an automated procedure for disassembling or assembling a stack of pallets. In some embodiments, process 1000 is implemented at least in part by system 200 of FIG. 2A , system 250 of FIG. 2B , system 275 of FIG. 2C , and/or system 800 of FIG. 8 .

At 1005, the system determines a particular stack to be moved from a source location to a destination location where the stack is unstacked. In some embodiments, unstacking a stack (e.g., a stack of pallets) includes controlling a robotic arm to pick items (e.g., pallets) from the stack and place those items at a determined destination location (e.g., according to A destination location determined for a plan for moving items). The particular stack to be moved from the source location will be one of the stacks buffered/assembled in a buffer strip, and for that stack the stack pusher system will be controlled to insert the stack into the stack mover system so that the stack mover system Move the stack to the destination location.

According to various embodiments, the system stores a data structure that the system uses to maintain/store: (i) a vehicle to manifest (e.g., a packing list or an indication of a group of items or items included in a vehicle). (ii) a mapping of a vehicle to a position within the system or a relative position of a position, (iii) a vehicle to a robot arm (e.g., assigned to stack items/ A mapping of the robot arm unstacking items from the vehicle, etc.), (iv) a mapping of the robot arm to a workspace or zone corresponding to a range of the robot arm, etc. The system monitors/tracks a position of a vehicle and accordingly updates data structures, such as maps and the like. The system uses data structures to track specific items (or items included in a specific item/vehicle) within the system, such as tracking a specific vehicle to which an item will be stacked, or one from which an item will be unstacked/obtained A specific vehicle (or associated manifest).

In conjunction with determining a plan for performing a stocking operation(s) relative to a carrier (e.g., unstacking a stack of pallets on a pallet stack), the system determines to insert the stack of pallets into the robotic stack mover system, and determine a position within the system's workspace to move the pallet stack to for the system to perform a stocking operation (e.g., to bring the pallet stack into range of a robot arm, so the system can control the robot arm to perform preparation operations). The system determines one of the specific stacks for which the stocking operation will be performed. As an example, the system selects a particular stack based on a manifest of one or more available stacks. As another example, the system determines a particular stack based on a stack queue (eg, the particular stack is the next stack in the stack queue for which a stocking operation is to be performed), and so on.

At 1010, the stack is moved to the destination location. In some embodiments, moving the stack to the destination location includes inserting the stack into a robotic stack mover system, such as into a predefined insertion location. For example, the system controls a robotic stack pusher system to insert (eg, push) a stack into an input (eg, a predefined insertion location) of the stack mover system. The system determines a destination location to move the stack to (eg, to a specific area in the workspace, or to a relative location, such as moving the stack to a predefined distance from a source or insertion location). In response to determining the location to move the stack to, the system controls the robotic stack mover system to move the stack to the destination location. For example, the system controls to drive the drive unit (e.g., a motor of the drive unit), thereby causing a drive chain to advance, which causes a pusher unit (e.g., a drive carriage) to apply a force to the stack to be moved and will Stack push/pull to destination location.

At 1015, a strategy and/or plan for moving a pallet from a source stack (eg, the stack selected at 1005) to a destination location is determined and executed. In some embodiments, the system determines a strategy for moving and grabbing the pallet. For example, the system plans and executes a set of maneuvers to move its end effector to a position above or otherwise close to one of the pallets to be grasped. Determine and implement a strategy for grabbing pallets. The system determines a plan (eg, trajectory, etc.) for moving pallets to a destination stack, and the system executes the plan. The trajectory/plan takes into account obstacles in the workspace, such as other stacks, and interactions with other robotic tools, such as another pick/place robot operating in the same workspace (e.g., robotic arms 202, 204 of FIG. 2A ) possible conflict.

At 1020, the system moves the stack within the workspace as the trays are unstacked from the stack. In some embodiments, 1020 is optionally performed, or the system waits until unstacking of the stack is complete.

According to various embodiments, if the system determines that the stack will be moved to improve the ability of a robot to reach the pallets of the stack or to move the stack within range of a different robot, the system determines that the stack will be moved when the pallet is unstacked (e.g., after all pallets have been de-stacked). Moves the stack since before the corresponding vehicle was unstacked. For example, referring to FIG. 2A , pallet stack 222 a is within range 206 of robot arm 202 . If the system determines that a pallet will be unstacked from pallet stack 222a and placed on destination pallet stack 240c, then the system determines to control the robotic stack mover system to move the pallet stack 222a into range 208 of the robotic arm 204, which may A pallet is unstacked from pallet stack 222a and placed on destination pallet stack 240c (eg, because destination pallet stack 240c is within range of robot arm 204 and outside range 206 of robot arm 202).

At 1025, the system determines that unstacking pallets from the stack is complete. For example, if the system determines that the stack is empty, the system determines that unstacking is complete. In some embodiments, determining that the stack is empty includes determining that all pallets that were determined to be unstacked from the stack have been successfully unstacked. The procedure 1000 is iteratively performed on steps 1015 and 1020 until the system determines that unstacking trays from the stack is complete.

At 1030, the vehicle is moved to a return position. In some embodiments, in response to determining that unstacking of the stack is complete, the system determines to move the vehicle (eg, the stack) to a return position. The system can pick up the vehicle by controlling the robotic arm, such as using an end effector located at the distal end of the robotic arm or using a structure attached to one side of the robotic arm (e.g., a hook mounted to the robotic arm). For example, a dolly with pallets stacked on it) to move the carrier to the return position. In some embodiments, the system controls a robotic stack mover system to move the vehicle. For example, in response to determining that unstacking is complete with respect to a vehicle, the system drives a motor of the robotic stack mover system to cause the drive chain to move, which in turn engages the vehicle and causes the vehicle to move. The system controls to drive the motor to drive the drive chain sufficiently to move the vehicle from a current position to a return position, such as to the end of the robotic stack mover system. The system includes a transport structure at the end of the robotic stack mover system that moves a carrier placed thereon to a return position.

At 1035, a determination is made as to whether procedure 1000 is complete. In some embodiments, the decision process 1000 will complete in response to a determination that there are no other stacks to unstack, a supervisor indicates that the process 1000 is to be paused or stopped, and the like. In response to a determination that process 1000 is complete, process 1000 ends. In response to a determination that process 1000 is not complete, process 1000 returns to step 1005 .

Figure 10B is a flowchart illustrating one embodiment of an automated procedure for disassembling or assembling a stack of pallets. In some embodiments, process 1050 is implemented at least in part by system 200 of FIG. 2A , system 250 of FIG. 2B , and/or system 275 of FIG. 2C .

At 1055, information about a stack is obtained. In some embodiments, the system determines a current location of the stack, with respect to a manifest associated with the stack (e.g., a set of pallets included on the stack, a set of items in one or more pallets on the stack, Information about a set of pallets to be stacked on a stack, a set of objects to be placed on a stack, etc.).

At 1060, the system determines a particular stack for which a stocking operation is to be performed. In some embodiments, the system selects one of the stacks for which the stocking operation will be performed. For example, the system selects one of the stacks for which the pallet will be unstacked. As another example, the system selects a stack on which to place one or more trays. The system selects a stack based on one or more of: (i) one of the queues for insertion into the robotic stack mover system, (ii) a manifest associated with the stack, (iii) a stack associated with the stack A priority of the manifest, (iv) a position of the stack (such as the position of the stack relative to the robotic stack mover system), etc.

At 1065, the stack is moved to a staging location within the workspace where a staging is to be performed. The system controls the robotic stack mover system to move the stack to the stocking position. As an example, a stock location corresponds to a location within a range of a robot (eg, robot arm 202 or robot arm 204 of system 200 of FIG. 2A ) used to perform a stock operation.

At 1070, information about the stack is stored in association with the unstack location. In some embodiments, the system updates a mapping of stacks to locations, such as a mapping of stacks to locations along the robot's path. The system uses one or more sensors (such as a vision system and/or a sensor) included in the robotic stack mover system to determine a position of the stack.

At 1075, one of the stocking operations performed with respect to the stack is complete. The system controls a robot (eg, robot arm 202 or robot arm 204 ) to pick and place items relative to the stack. For example, the system uses a robot to unstack a set of one or more pallets from the stack. As another example, the system uses a robot to place a pallet on a stack.

At 1080, the vehicle for stacking is moved to a return position. In some embodiments, the system determines to move the vehicle (eg, the stack) to a return position in response to determining that the stocking operation relative to the stack is complete. The system can pick up the vehicle by controlling the robotic arm, such as using an end effector located at the distal end of the robotic arm or using a structure attached to one side of the robotic arm (e.g., a hook mounted to the robotic arm). For example, a dolly with pallets stacked on it) to move the carrier to the return position. In some embodiments, the system controls a robotic stack mover system to move the vehicle. For example, in response to determining that unstacking is complete with respect to a vehicle, the system drives a motor of the robotic stack mover system to cause the drive chain to move, which in turn engages the vehicle and causes the vehicle to move. The system controls to drive the motor to drive the drive chain sufficiently to move the vehicle from a current position to a return position, such as to the end of the robotic stack mover system. The system includes a transport structure at the end of the robotic stack mover system that moves a carrier placed thereon to a return position.

At 1085, a determination is made as to whether procedure 1050 is complete. In some embodiments, the decision procedure 1050 will complete in response to a decision that there are no other stacks to unstack, an administrator has indicated that the procedure 1050 is to be paused or stopped, and the like. In response to a determination that procedure 1050 is complete, procedure 1050 ends. In response to a determination that process 1050 is not complete, process 1050 returns to 1055 .

11 is a flowchart of a procedure for loading a stack into a workspace, according to various embodiments. In some embodiments, process 1100 is implemented by system 200 of FIG. 2A , system 250 of FIG. 2B , system 275 of FIG. 2C , and/or system 800 of FIG. 8 .

At 1110, a determination is made to load a stack into a workspace. In response to determining that the robotic arm will be used to perform pick and place operations with respect to items to be moved to/from the stack, the system determines to load a stack into the workspace, such as a stack mover system. The system is based on information obtained by one or more sensors in the workspace, such as sensors included in one or more of a stack pusher system, a stack mover system, a buffer strip, etc. Instead, it is decided to load the stack into the workspace. The system determines to load the stack into the workspace in response to determining that the robotic arm in the workspace has completed loading/unloading one (s) of the stacks in the workspace (eg, performing a stocking operation).

At 1120, a stack pusher is controlled to load the stack from a stack buffer into the workspace. The system robotically controls a stack pusher system to advance the stack from a starting position corresponding to the stack buffer strip where the stack is queued/assembled to a final position corresponding to an input of a stack mover system ( or otherwise advance to one of the workspace inputs). Controlling the stack pusher includes controlling an actuation device to actuate and generate a linear force that advances one or more pusher structures toward the stack and the input.

At 1130, a determination is made as to whether the stack was successfully loaded into the workspace. The system uses sensors included in the workspace and/or a stack mover system to which the stack is to be loaded in conjunction with determining whether the stack was successfully loaded. For example, the system uses a vision system to generate a model of the workspace, and the system then determines based on the model whether the stack is properly/completely inserted into the workspace. As another example, the system uses information obtained from a sensor in a stack mover system to determine whether the stack is properly loaded so that the pusher unit of the stack mover system engages the stack and moves the stack through the workspace .

At 1140, a determination is made as to whether procedure 1100 is complete. In some embodiments, in response to a determination that no other stacks (e.g., stacks of pallets, receptacles, etc.) ) to move (eg, no other trays to unload), a user has left the system, an administrator has instructed to pause or stop the process 1100, etc., the decision process 1100 will be complete. In response to a determination that process 1100 is complete, process 1100 ends. In response to a determination that process 1100 is not complete, process 1100 returns to 1110 .

Figure 12 is a flowchart of a procedure for loading a stack into a workspace, according to various embodiments. In some embodiments, process 1200 is implemented by system 200 of FIG. 2A , system 250 of FIG. 2B , system 275 of FIG. 2C , and/or system 800 of FIG. 8 .

At 1210, a determination is made to load a stack into a workspace. In some embodiments, 1210 corresponds to or is similar to 1110 of procedure 1100 of FIG. 11 .

At 1220, a stack buffer is controlled to load the stack to a position where a stack pusher engages the stack. In response to determining that the stack is to be loaded into the workspace, the system determines whether the stack is in one of the positions where the stack pusher system engages the stack to advance the stack toward the stack mover system or the workspace. In response to determining that the stack is not in a position where the stack pusher engages the stack, the system controls a buffer transport device in a buffer zone to advance the stack to be loaded into position.

At 1230, the stack pusher is controlled to load the stack from the stack buffer into the workspace. In response to determining that a stack is located in the stack buffer such that the stack pusher engages/advances the stack, the system robotically controls the stack pusher to advance the stack from its location in the buffer strip to the workspace (e.g., to the stack mover One of the input terminals of the system). In some embodiments, 1230 corresponds to or is similar to 1120 of procedure 1100 of FIG. 11 .

At 1240, a determination is made as to whether the stack was successfully loaded into the workspace. In some embodiments, 1240 corresponds to or is similar to 1140 of procedure 1100 of FIG. 11 .

In response to determining at 1240 that the stack was not successfully loaded into the workspace, the process 1200 returns to 1230 and the process 1200 iterates at 1230-1240 until the system determines that the stack is successfully loaded into the workspace.

In response to determining at 1240 that the stack was successfully loaded into the workspace, process 1200 proceeds to 1250 where a determination is made as to whether process 1200 is complete. In some embodiments, in response to a determination that no other stacks (e.g., stacks of pallets, receptacles, etc.) ) to move (eg, no other trays to unload), a user has left the system, an administrator has instructed to pause or stop the process 1200, etc., the decision process 1200 will be complete. In response to a determination that process 1200 is complete, process 1200 ends. In response to a determination that process 1200 is not complete, process 1200 returns to 1210 .

Figure 13 is a flowchart of a procedure for loading a stack into a workspace, according to various embodiments. In some embodiments, process 1300 is implemented by system 200 of FIG. 2A , system 250 of FIG. 2B , system 275 of FIG. 2C , and/or system 800 of FIG. 8 .

At 1305, a determination is made to control a stack pusher to load a stack to a destination location in a workspace. In some embodiments, 1210 corresponds to or is similar to 1110 of procedure 1100 of FIG. 11 .

At 1310, stack pusher status information is obtained from one or more sensors. The system gets information about the workspace or state of the system. The system includes a vision system or other sensors, including one or more of the following: sensors included in a stack pusher system, sensors included in a buffer zone, sensors included in a Sensors in stack mover systems, and/or sensors mounted to (or close to) robotic arms in the workspace, etc.

At 1315, a determination is made as to whether the stack pusher is configured in one of the retracted states. The system determines whether the stack pusher is in a retracted state based at least in part on: (i) image data of the workspace (e.g., obtained using a vision system), (ii) one of the stack pusher systems included or a plurality of sensors, and/or (iii) one or more sensors included in the buffer zone. For example, the system determines whether one or more pusher structures are in an expanded position (eg, relative to a base plate of a stacked pusher system).

In response to determining at 1315 that the stack pusher is configured in the retracted state, routine 1300 proceeds to 1320 where a stack pusher control is activated to configure the stack pusher in the retracted state. In response to configuring the stack pusher system in the retracted state, the system actuates an actuation device to apply a linear force to the one or more pusher structures to direct the pusher structures toward a base plate of the stack pusher system retract.

In response to determining at 1315 that the stack pusher is configured in the retracted state, routine 1300 proceeds to 1325 where a determination is made as to whether a gate (eg, a stack gate) is open. The system determines whether the gate is open based at least in part on (i) image data of the workspace (e.g., obtained using a vision system), (ii) one or more sensors included in the stack pusher system, (iii) one or more sensors included in the buffer zone, and/or (iv) one or more sensors included in a stack mover system (e.g., which moves the stack through the workspace) detector. The gates are included in a gating structure that regulates the traffic/flow of stacks from the buffer zone to the stack mover system.

In response to determining that the gate is not open, routine 1300 proceeds to 1330 where a gate control is actuated to open the gate. Process 1300 thereafter returns to 1325 and process 1300 iterates at 1325 to 1330 until it is determined that the gate is open. For example, the system robotically controls the opening of a gate to allow the stack pusher system to engage the stack and/or advance the stack to the stack mover system. The system controls the opening/closing of the gates in coordination with controlling the stack pusher system and/or the stack mover system.

In response to determining that the gate is open, routine 1300 proceeds to 1335 where the stack pusher control is actuated to configure the stack pusher in the expanded state.

At 1340, a determination is made as to whether the stack was successfully loaded into the workspace. In some embodiments, 1340 corresponds to or is similar to 1110 of procedure 1100 of FIG. 11 .

In response to determining at 1340 that the stack was successfully loaded into the workspace, the process 1300 returns to 1335 and the process 1300 iterates at 1335 to 1340 until the system determines that the stack is successfully loaded into the workspace.

In response to determining at 1340 that the stack was successfully loaded into the workspace, routine 1300 proceeds to 1345 where a determination is made as to whether routine 1300 is complete. In some embodiments, in response to a determination that no other stacks (e.g., stacks of pallets, receptacles, etc.) ) to move (eg, no other trays to unload), a user has left the system, an administrator has instructed to pause or stop the process 1300, etc., the decision process 1300 will be complete. In response to a determination that process 1300 is complete, process 1300 ends. In response to a determination that process 1300 is not complete, process 1300 returns to 1305 .

While the foregoing embodiments have been described in connection with grabbing, moving, and placing one or more trays, various other receptacles or containers may be implemented. Examples of other receptacles or containers include bags, boxes, pallets, crates, and the like.

Various examples of the embodiments described herein are illustrated in conjunction with flowcharts. Although examples may include certain steps performed in a particular order, according to various embodiments, various steps may be performed in various orders and/or various steps may be combined into a single step or performed in parallel.

Although the foregoing embodiments have been set forth in some detail for purposes of clarity of understanding, the invention is not limited to the details provided. There are many alternative ways of implementing the invention. The disclosed embodiments are illustrative and not restrictive.

100: system 102: Source Pallet Stack/Pallet Stack 104: Source Pallet Stack/Pallet Stack 106: Enter stack transporter/transporter 108: input terminal 110: track 112: Robot Arm 114: Robot Arm 116: Tray handling end effector / end effector 118: Tray handling end effector/end effector 120: Destination pallet stack 122: Destination pallet stack 124: Arrow 126: 3D camera/camera 128: Control Computer 140: Source stack 142: Destination Stack 200: system 202: Robot Arm 204: Robot Arm 205: track 206: range 208: range 210: Robotic Stack Mover System 212: Drive unit 214: Tensioning unit 216: Guide track 217: Drive chain 218a: Thruster unit 218b: Thruster unit 218c: Thruster unit 218d: Thruster unit 220: pallet stack/stack 222a: Pallet stack 222b: Pallet stack 222c: Pallet stack 222d: Pallet stack reserved position 230: Robotic Stack Mover System 232: Drive unit 234: tensioning unit 236: Guide track 237: Drive chain 238a: Thruster unit 238b: Thruster unit 238c: Thruster unit 240a: Destination pallet stack 240b: Destination pallet stack 240c: Destination pallet stack 245: Vision System 246: camera 248: Control Computer 250: system 252: Transport Structures 254a: Pallet stack 254b: Pallet stack 254c: Pallet stack 256: Autonomous Pallet Stack Insertion Unit 275: System 280: Transport Structures 282a: Objects 282b: Object 282c: Objects 282d: Objects 282e: Object 300: Stack Pusher System/Robot Stack Pusher System/System 305: Actuating device 310: Thruster structure 315: Propulsion mechanism 320: stack 325: Tray 400: System 410: drive unit 412: Support structure 414: Motor 420: tensioning unit 432a: Track foot 432b: Track foot/feet 432c: Track foot 432d: Track foot 432e: Track foot 442a: Thruster unit 442b: Thruster unit 442c: Thruster unit 442d: Thruster unit 500: Robot Stack Thruster System 505: Base plate 510: Actuating device 515: First thruster structure 520: Stack Engaging Thruster Structure 525: Stack/Vehicle 600: Stack Thruster System 605: Base plate 610a: Drawer slides 610b: Drawer slides 615: Actuating device 620: First thruster structure 625a: Drawer slides 625b: Drawer slides 627a: Wheels 627b: Wheels 630: Stack Engaging Thruster Structures 631a: pulley 631b: Pulley 631c: pulley 631d: Pulleys 635a: Wheels 635b: Wheels 655: Shutter 700: Stack Pusher System/System/Stack Engagement Pusher 705: Actuating device 715: First Thruster 720: Stack Engagement Thruster 725: stack 750: Starting position 755: final position 760: Distance 765: Depth/Maximum Depth 770: stack 800: system 802: Robot Arm 804: Robot Arm 806: range 808: range 810: Stack Mover Systems / Stack Pusher Systems / Robotic Stack Mover Systems 812: drive unit 814: tensioning unit 816: Guide rail 817: Drive chain 818: Thruster Unit 822a: Pallet stack 822b: Pallet stack 822c: Pallet stack 822d: Pallet stack reserved position 845: Vision System 846: camera 848: Control Computer 850: Stack Pusher System/Robot Stack Pusher System 855: Gating Structure 860: buffer zone 900: State Schema 902: Program Status/Program/Mod/Status 904: Status/Program/Module 906: Status/Program/Module 908: Status/Program/Module 910: Status/Program/Module 915: State Schema 917: Program Status/Program/Mod 919: status 921: status 923: status 925: status 1000: program 1005: Steps 1010: Steps 1015: Step 1020: Steps 1025: Step 1030: Steps 1035: Step 1050: Procedure 1055: Step 1060: Steps 1065: Steps 1070: Steps 1075: Steps 1080: steps 1085: Steps 1100: Program 1110: Steps 1120: Steps 1130: Steps 1140: Steps 1200: program 1210: Step 1220: Step 1230: Step 1240: Step 1250: step 1300: Procedure 1305: Step 1310: Step 1315: Step 1320: Step 1325: step 1330: Step 1335: step 1340: Step 1345: step

Various embodiments of the invention are disclosed in the following detailed description and accompanying drawings.

FIG. 1A is a block diagram illustrating a robot production line material preparation system according to the related art.

FIG. 1B is a block diagram illustrating a robot production line material preparation system according to the related art.

2A is a block diagram illustrating a robotic production line material preparation system according to various embodiments.

2B is a block diagram illustrating a robotic production line material preparation system according to various embodiments.

2C is a block diagram illustrating a robotic production line material preparation system according to various embodiments.

Figure 3A is a block diagram illustrating a stack pusher system according to various embodiments.

Figure 3B is a block diagram illustrating a stack pusher system according to various embodiments.

Figure 4 is a block diagram illustrating one embodiment of a stack mover system.

Figure 5A illustrates a diagram of a stack pusher in accordance with various embodiments.

Figure 5B illustrates a diagram of a stack pusher in accordance with various embodiments.

Figure 6A illustrates a diagram of a stack pusher in an expanded state, according to various embodiments.

Figure 6B illustrates a diagram of a stack pusher in a retracted state, according to various embodiments.

6C is a diagram illustrating a front view of a stack pusher in a retracted state, according to various embodiments.

Figure 6D illustrates a diagram of a stack pusher in accordance with various embodiments.

Figure 6E illustrates a diagram of a stack pusher in accordance with various embodiments.

Figure 7 illustrates a diagram of a stack pusher according to various embodiments.

Figure 8 illustrates a diagram of a stack pusher and a stack mover according to various embodiments .

Figure 9A is a state diagram illustrating one embodiment of an automated process for moving a stack of pallets.

Figure 9B is a state diagram illustrating one embodiment of an automated process for assembling a stack of pallets.

Figure 10A is a flowchart illustrating one embodiment of an automated procedure for disassembling or assembling a stack of pallets.

Figure 10B is a flowchart illustrating one embodiment of an automated procedure for disassembling or assembling a stack of pallets.

11 is a flowchart of a procedure for loading a stack into a workspace, according to various embodiments.

Figure 12 is a flowchart of a procedure for loading a stack into a workspace, according to various embodiments.

Figure 13 is a flowchart of a procedure for loading a stack into a workspace, according to various embodiments.

500: Robot Stack Thruster System

505: base plate

510: Actuating device

515: The structure of the first thruster

520:Stack Engagement Thruster Structure

525:Stack/Vehicle

Claims (37)

A robotic stack pusher system comprising: an actuating device; and a plurality of pusher structures that are substantially planar, wherein at least one of the plurality of pusher structures nests within one or more other of the plurality of pusher structures; in: the actuation device is operatively coupled to at least one of the plurality of pusher structures; the actuation device is configured to actuate a position of the plurality of pusher structures between a retracted state and an expanded state in response to a control signal; and Actuation of the actuator device causes the nested one of the plurality of structures to telescopically expand and controllably propel a payload with sufficient force. The robotic stack pusher system of claim 1, wherein the payload is a wheeled trolley on which one or more receptacles are stacked. The robot stack pusher system of claim 2, wherein the plurality of pusher structures includes a payload engaging pusher structure that engages the wheeled dolly and propels the wheeled dolly to a robot work space. The robotic stack pusher system of claim 3, wherein the payload engaging pusher structure engages the wheeled dolly and does not engage the one or more receptacles stacked on the wheeled dolly. The robotic stack pusher system of claim 1, wherein the control signal is received from a robotic control system. The robot stack pusher system of claim 5, wherein the robot control system is associated with a robot workspace, and the robot control system uses one or more sensors from the robot workspace in conjunction with generating the control signal information obtained. The robotic stack pusher system of claim 6, wherein the robotic control system uses the information obtained from one or more sensors to detect a payload in a buffer zone ready to be pushed. The robot stack pusher system according to claim 7, wherein the robot control system determines to control the robot stack push through the control signal in response to detecting that the payload is located in the buffer zone and is ready to be pushed into the workspace device. The robotic stack pusher system of claim 1, wherein the actuating device includes a linear shaft. The robot stack pusher system according to claim 9, wherein the linear axis is a pneumatic axis or a hydraulic axis. The robotic stack pusher system of claim 9, wherein the linear axis is configured to expand or retract along a direction in which the plurality of pusher structures travel between the retracted state and the expanded state. The robotic stack pusher system of claim 1, further comprising one or more processors configured to: determine that the payload is loaded into a robot workspace; and In response to determining that the payload is loaded into the robotic workspace, the actuation device is controlled to actuate a linear axis to move the plurality of thruster structures to the expanded state. As the robot stack pusher system of claim 12, wherein: the plurality of pusher structures includes at least a first pusher structure and a payload engaging pusher structure; The payload engaging pusher structure is configured to engage the payload and propel the payload into the robotic workspace in response to the actuation device being actuated to move the plurality of pusher structures to the expanded state one of the destination locations; and In response to being controlled to actuate the position of the plurality of pusher structures, the actuation device causes telescopic movement of the plurality of pusher structures to the expanded state. The robotic stack pusher system of claim 13, wherein in response to a determination that the payload has been loaded to the destination location, the one or more processors control the actuating device to actuate to actuate the plurality of The position of the pusher structure is moved to the retracted state. As the robot stack pusher system of claim 12, wherein: the plurality of pusher structures includes at least a first pusher structure and a payload engaging pusher structure; and In response to moving from the retracted state to the expanded state, the first pusher structure and the payload engaging pusher structure are sequentially telescopically expanded to an expanded position. The robotic stack pusher system of claim 15, wherein in response to moving from the expanded state to the retracted state, the first pusher structure and the payload engaging pusher structure are sequentially retracted to a retracted position . The robotic stack pusher system of claim 16, wherein the payload engaging pusher structure has a width greater than the first pusher structure, and when the payload engaging pusher structure and the first pusher structure are in the When in the retracted state, the payload engaging pusher structure at least partially encloses the first pusher structure. The robotic stack pusher system of claim 15, wherein the first pusher structure and the payload engaging pusher structure are nested structures that expand in sequence to move the payload engaging pusher structure One of the distal ends engages the payload and propels the payload into the robot workspace. As the robot stack pusher system of claim 12, wherein: the plurality of pusher structures includes at least a first pusher structure and a payload engaging pusher structure; and in response to being controlled to actuate the position of the plurality of pusher structures, the actuator device applies a consistent force to a linear shaft to cause the linear shaft to expand from the retracted state to the expanded state, The linear shaft is coupled to the payload-engaging pusher structure such that the actuation force that causes the linear shaft to expand to the expanded state causes the payload-engaging pusher structure to move relative to the first pusher structure to an intermediate path Extended state. As the robot stack pusher system of claim 19, wherein: the payload engaging pusher structure and the first pusher structure are commonly coupled to a base plate; the payload engaging propeller structure is operatively coupled to the first propeller structure; and In response to the payload engaging pusher structure being expanded beyond the intermediate expanded state, the payload engaging pusher structure applies a pulling force to cause the first pusher structure to retract relative to the base plate from a first The state moves to a first extended state. As the robot stack pusher system of claim 12, wherein: the plurality of pusher structures includes a first pusher structure, one or more intermediate pusher structures, and a payload engaging pusher structure; The plurality of pusher structures are configured to be in a nest when the first pusher structure, the one or more intermediate pusher structures, and the payload engaging pusher structure are collectively in the retracted state In the configuration; in response to being controlled to actuate the position of the plurality of pusher structures, the actuator device applies a consistent force to a linear shaft to cause the linear shaft to expand from the retracted state to the expanded state; and The linear shaft is coupled to at least one of the first pusher structure, the one or more intermediate pusher structures, and the payload engaging pusher structure such that the actuation force causes the linear shaft to expand to the expanded state The first pusher structure, the one or more intermediate pusher structures, and the payload-engaging pusher structure are caused to sequentially expand from the nested configuration to move to the expanded state. The robotic stack thruster system of claim 21, wherein the first thruster structure, the one or more intermediate thruster structures, and the payload engaging thruster structure are connected via one or more steel wire cables or chains, when The one or more wire rope cables or chains engage the propellers sequentially with the first propeller structure, the one or more intermediate propeller structures and the payload as the plurality of propeller structures move to the expanded state The structure exerts a linear force. The robotic stack pusher system of claim 1, wherein at least one pusher structure of the plurality of pusher structures is connected to one or more wheels supporting the at least one pusher structure. As the robot stack pusher system of claim 1, it further includes: A gating structure gates the introduction of the payload into a robot workspace. The robotic stack pusher system of claim 24, wherein the gating structure is configured to prevent the payload from entering the robotic workspace until the control signal is received in response to loading the payload into One of the robot's workspaces is determined to be generated. The robotic stack pusher system of claim 24, wherein in response to a determination that the payload is to be loaded into the robotic workspace, the gate structure is actuated to move to an open state, and the actuating device is then controlled to The position of the plurality of pusher structures is actuated to the expanded state. The robotic stack pusher system of claim 1, wherein the robotic stack pusher system advances the payload to insert the payload into a robotic workspace, and the robotic workspace includes a robotic stack mover system, the robotic stack A mover system moves one or more payloads within an operational range of one or more robots. The robotic stack pusher system of claim 27, further comprising one or more processors configured to coordinately operate the robotic stack pusher system and the robotic stack mover system to move One or more payloads are moved to and through the robotic workspace. As the robot stack pusher system of claim 28, wherein: the one or more processors are further configured to control a buffer zone transport structure to move the payload to an engaged position where the plurality of pusher structures engage the payload; and The one or more processors control the buffer zone transport structure in coordination with controlling the robotic stack pusher system and the robotic stack mover system. A method comprising: determining to advance a payload into a robot workspace; In response to determining that the payload is to be advanced into the robotic workspace, controlling a robotic stack thruster system to move a plurality of thruster structures to cause the payload to advance from a payload buffer zone to a final position; and The robotic stack pusher system is controlled to apply a retraction force to retract the one or more pusher structures to a starting position. The method of claim 30, wherein controlling a robotic stack pusher system to move the plurality of pusher structures to cause the payload to advance from a payload buffer zone to a final position comprises: transmitting a control signal to the robotic stack pusher system to cause an actuation device of the robotic stack pusher system to position one of the plurality of pusher structures between a retracted state and an expanded state in response to the control signal between activations. The method of claim 30, wherein: the final position corresponds to a payload introduction position of a robotic stack mover system; and The stack pusher system is controlled to apply the retracting force in response to determining that the payload is engaged by a structure in the robotic stack mover system. The method of claim 30, wherein a gating structure is controlled to actuate a gate configured in an open position, and the robotic stack pusher system is controlled in response to the gate being configured in the open position One of them determines to move the plurality of thruster structures. The method of claim 30, wherein the determining to load the payload into the robot workspace includes receiving one or more control signals generated based on a model of the robot workspace. The method of claim 34, wherein the model of the robot workspace is generated based at least in part on information obtained by one or more sensors in the robot workspace or the stack pusher system. The method of claim 34, wherein the one or more control signals are generated in response to a determination that a robot in the robot workspace has completed a stocking operation with respect to another payload. A computer program product embodied in a non-transitory computer readable medium and including computer instructions for: determining to advance a payload into a robot workspace; In response to determining that the payload is to be advanced into the robotic workspace, controlling a robotic stack thruster system to move a plurality of thruster structures to cause the payload to advance from a payload buffer zone to a final position; and The robotic stack pusher system is controlled to apply a retraction force to retract the one or more pusher structures to a starting position.